Fully Integrated Mill Automation Projects
We offer end-to-end automation solutions for newly established or completely renovated mill facilities:
Greenfield Projects: For facilities built from scratch, we develop fully integrated automation systems designed using the latest technologies. We meticulously manage all details from the project planning phase to the commissioning process.
Turnkey Integrated Solutions: We offer complete packages covering hardware, software, installation, commissioning, and training. With single-source management, we minimize project risks and eliminate coordination problems arising from responsibility distribution.
Raw Material to Shipping Automation: We automate all processes covering grain acceptance, cleaning, conditioning, grinding, packaging, and shipping within an integrated system. This holistic approach makes data flow seamless and ensures inter-process synchronization.
Specially designed projects to increase operational efficiency:
Energy Efficiency: We achieve significant cost savings by installing systems that monitor, analyze, and optimize energy consumption.
Quality Consistency: By automatically controlling process parameters, we enable you to achieve consistent product quality even under variable raw material conditions.
Efficiency Improvement: We develop automation projects that analyze and minimize production losses, optimizing yield.
Capacity Increase: We help you achieve capacity increases without additional investment by ensuring existing equipment operates at maximum efficiency.
Advanced technology solutions for transitioning to future smart factories:
IIoT Applications: We offer Industrial Internet of Things solutions that connect equipment and sensors, collect and analyze data.
Data Analytics: We develop advanced analytics platforms that transform your operational data into meaningful business insights.
Digital Twin: We create virtual copies of your physical facility, providing simulation and optimization opportunities.
Predictive Maintenance: We install smart maintenance systems that detect equipment failures in advance and minimize unplanned downtime.
Needs Analysis and Project Planning
The first step of a successful automation project is proper needs analysis:
Determining Business Objectives: We identify your priority goals such as efficiency improvement, quality enhancement, and cost optimization.
Current Situation Analysis: We conduct a comprehensive evaluation of your facility to identify improvement opportunities.
Feasibility Study: We calculate the return period of your investment through technical and economic feasibility analyses.
Risk Management: We take proactive measures by identifying potential risks in advance.
Automation system design customized for your facility:
System Architecture: We design scalable and future-compatible automation architecture suitable for your needs.
Hardware and Software Selection: We select reliable equipment and software platforms that comply with industrial standards.
Control System Design: We develop intuitive interfaces and effective control strategies that operators can easily use.
Communication Infrastructure: We design secure, fast, and reliable network infrastructure.
Bringing the project to life and seamless commissioning:
Hardware Installation: We perform equipment assembly and cable installation work with our professional teams.
Software Development: We develop control software, SCADA systems, and reporting tools specific to your facility.
Testing and Validation: We validate all system functions through comprehensive test protocols.
Phased Commissioning: We apply step-by-step commissioning methodology that minimizes production interruption.
Knowledge transfer for sustainable success of the system:
Operator Training: We provide hands-on training for users to effectively use the system.
Maintenance Personnel Training: We enable technical teams to perform system maintenance and first-level troubleshooting.
Documentation: We prepare comprehensive user manuals, maintenance procedures, and reference materials.
Continuous Support: We guarantee optimal system performance through remote and on-site support services.
Raw Material Acceptance and Pre-processing Automation
Quality and efficiency from the first stage of your facility:
Automatic Weighing and Sampling: We ensure quality control through automatic weighing of incoming raw materials and representative sampling.
Grain Reception and Storage: We install systems that make optimal silo assignments based on quality parameters and monitor stock levels in real-time.
Cleaning Systems: We provide automatic control of foreign matter separation and cleaning equipment.
Conditioning Automation: We develop conditioning systems that dynamically adjust according to raw material characteristics and provide precise moisture control.
Turnkey Automation Projects & Solutions for Mill Facilities
In modern mill facilities, automation systems play a critical role in terms of efficiency, quality consistency, and cost optimization. Businesses seeking to stand out in competitive markets focus on elevating their operational excellence by transitioning from manual processes to automatic control systems.
As Tanış A.Ş., with over 60 years of experience in the milling industry, we develop and implement turnkey automation projects customized for your facilities. With our integrated solutions that optimize all your processes from raw material acceptance to shipping, we add measurable value to your business.
Grinding and Processing Operations Automation
Automation for operations at the heart of mill processes:
Roll Control Systems: We install automatic control systems for roll gap, feed rate, and load balance.
Yield Control: We develop control algorithms that continuously monitor production parameters to achieve optimal yield.
Product Flow Control: We design routing and distribution systems that optimize product flow throughout the facility.
Sifting Automation: We install systems that monitor and control sieve performance, improving classification efficiency.
Automatic quality systems for consistent product quality:
Online Measurement Systems: We install systems that measure quality parameters within the process and provide real-time monitoring.
Laboratory Integration: We integrate your laboratory instruments with your automation system, eliminating manual data entry.
Quality Deviation Management: We develop alarm systems that instantly detect deviations in quality parameters and provide intervention opportunities.
Automatic Sampling: We install systems that automatically take samples from production lines at specific intervals and analyze them.
Integrated solutions for the final stages of production:
Packaging Lines: We design fully automatic systems for filling, weighing, labeling, and packaging.
Palletizing Systems: We install robotic systems for automatic stacking and stretch-wrapping of packages.
Warehouse Management: We develop automatic systems for inventory tracking, shelf life control, and optimal warehouse utilization.
Shipping Automation: We offer integrated solutions for order preparation, loading, and shipment tracking.
Control Systems and PLC Applications
The foundation of modern mill automation:
Industrial PLC Systems: We install reliable and durable control systems that comply with industrial standards.
Distributed Control: We design modular and flexible control architecture that integrates different parts of the facility.
Operator Interfaces: We develop user-friendly, intuitive HMI and control panels.
Redundant Control: We install redundant control structures that guarantee uninterrupted operation for critical systems.
Monitoring and management of the entire facility from a single point:
Central Monitoring Platform: We provide the ability to monitor all processes and equipment from a single screen.
Real-time Data: We install systems that collect and visualize production parameters instantly.
Alarm Management: We develop alarm systems that quickly detect abnormal conditions and guide operators.
Reporting: We offer tools that automatically generate production, quality, and performance reports.
Integrated solutions for production management and business processes:
Manufacturing Execution Systems: We install systems that manage work orders and perform recipe control.
Production Planning: We develop tools that create optimal production plans based on capacity, raw materials, and order status.
OEE Monitoring: We install systems that monitor equipment effectiveness in real-time and analyze performance losses.
ERP Integration: We ensure data integrity by integrating production data with your business systems.
Operational Efficiency and Performance Improvement
Key benefits provided by our automation projects:
Labor Efficiency: By automating manual operations, we enable personnel to focus on more value-added tasks.
Reduced Downtime: We reduce unplanned downtime through predictive maintenance and immediate intervention.
OEE Improvement: We achieve improvement in Overall Equipment Effectiveness.
Standardization: We achieve consistent operations independent of human factors and repeatable results.
Effects of our quality-focused automation solutions:
Precise Control: We ensure quality consistency through precise control of process parameters.
Waste Reduction: We achieve 15-30% reduction in waste rates through automatic quality control.
Customer Satisfaction: We increase customer satisfaction through consistent product quality.
Competitive Advantage: We create competitive superiority in the market through high quality standards.
Financial returns of your automation investment:
Labor Savings: We achieve 20-40% reduction in labor costs through automated processes.
Resource Optimization: We achieve 3-8% savings in raw material and auxiliary material usage.
Energy Efficiency: We provide 8-15% reduction in energy consumption through smart control systems.
Maintenance Optimization: We reduce maintenance costs by 20-35% through predictive maintenance.