In modern mill facilities, pneumatic systems perform many critical functions from raw material handling to product routing, from dosing to filtration. With their efficient, reliable, and flexible characteristics, pneumatic automation systems form the backbone of mill operations.
As Tanış A.Ş., with our over 60 years of industry experience, we offer advanced pneumatic automation solutions customized for your mill facilities. With our pneumatic systems that optimize all your processes from raw material acceptance to final product shipping, we increase your business’s efficiency, quality, and profitability.
Pneumatic Conveying Systems
We offer pneumatic conveying solutions designed according to different needs in mill facilities:
Positive Pressure Systems: High-capacity compressed air-assisted systems that enable transport of raw materials and intermediate products from single point to multiple destinations.
Negative Pressure (Vacuum) Systems: Vacuum conveying solutions that provide transport from multiple sources to a single destination, minimize dust emissions, and offer clean working environment.
Combination Systems: Hybrid solutions combining the advantages of both technologies for maximum flexibility and efficiency.
Dense Phase / Dilute Phase Technologies: Conveying systems optimized according to material characteristics, featuring low-velocity dense phase or high-velocity dilute phase transport.
Multi-product Management: Automatic line cleaning and product separation technologies that enable different products to be transported using the same system without contamination risk.
Advanced pneumatic routing solutions for precise control of product flow:
Pneumatic Valves and Routing Elements: Routing systems that control product flow quickly and precisely, durable and maintenance-free.
Locked Routing Systems: Secure transition mechanisms that prevent cross-contamination and provide locking between product lines.
Rotary Valves: Rotary valves that provide controlled feeding of raw materials and products, maintaining pressure differences to increase system efficiency.
Pneumatic Actuators: Long-lasting and reliable pneumatic actuators that precisely control valves and dampers.
Fluidized Bed Systems: Special conveying and routing systems where products are suspended in air to gain fluid characteristics, minimizing friction.
Pneumatic solutions for precise mixing and recipe control:
Precision Dosing Technologies: Pneumatic dosing systems that enable precise proportional mixing of additives and ingredients.
Continuous and Batch Dosing: Flexible systems capable of continuous or batch dosing according to production needs.
Gravimetric and Volumetric Systems: Solutions providing precise dosing with weight or volume-based precision measurement systems.
Pneumatic Weighing Systems: Durable weighing technologies that perform fast and precise weight measurement, unaffected by vibration.
Micro Dosing: Special systems for precise dosing of low-quantity ingredients such as vitamins, minerals, and additives.
Integrated solutions for clean and safe working environment:
Pneumatic Filter Cleaning: Automatic compressed air cleaning systems that maintain continuously high filtration efficiency.
Jet Pulse Filtration: Technology that ensures effective filter cleaning with short and powerful air pulses.
Cyclone and Multi-cyclone Separators: Centrifugal technology systems that efficiently separate products and air, requiring no maintenance.
HEPA Filtration: High-efficiency filtration systems that capture micron-level particles.
Dust Collection and Recovery: Systems that collect dust in the production environment, providing both a clean working area and minimizing product loss.
Digital Pneumatic Control Systems
The convergence of traditional pneumatic systems with digital technologies:
Programmable Control Units: Programmable controllers that provide central control of pneumatic systems.
Proportional Control: Digital technologies that provide precise proportional control of pressure, flow, and speed.
Pneumatic Fieldbus Systems: Industrial communication networks that enable digital communication between different components of the system.
Digital Valve Terminals: Modular digital valve stations that can be managed from central control.
Smart Sensor Networks: Smart sensors that monitor system performance and condition, detecting failures in advance.
Innovative pneumatic technologies that reduce energy costs:
Efficient Compressor Technologies: Modern compressors that optimize energy consumption with variable speed drives and smart control systems.
Pressure Optimization: Systems that automatically adjust pressure levels according to need, preventing unnecessary energy consumption.
Air Consumption Monitoring: Monitoring systems that track compressed air usage, detect leaks, and optimize consumption.
Energy Recovery: Systems that recover heat produced by compressors for use as heating or process heat.
Smart Pressure Reduction: Systems that optimize pressure according to equipment needs, providing efficiency through local pressure reduction instead of central high pressure.
Pneumatic solutions for future smart factories:
IoT-enabled Equipment: Smart pneumatic components that can be monitored over the internet and controlled remotely.
Predictive Maintenance: Systems that continuously monitor equipment performance to detect potential failures in advance and predict maintenance needs.
Digital Twin Technology: Technology that creates virtual copies of physical pneumatic systems, offering simulation and optimization opportunities.
Cloud-based Monitoring: Storage, analysis, and reporting of pneumatic system performance data on cloud platforms.
Machine Learning: Artificial intelligence algorithms that analyze operational data to continuously improve system performance.
Hybrid Pneumatic-Electric Systems
Solutions combining the advantages of different technologies:
Servo-pneumatic Technologies: High-performance hybrid systems that combine pneumatic power with servo precision.
Electro-pneumatic Positioning: Electronically controlled pneumatic systems for applications requiring precise position control.
Hybrid Drive Mechanisms: Efficient drive systems that optimally use pneumatic and electric power.
Smart Electro-pneumatic Valves: Modern valve technologies that are electronically controlled, energy efficient, and communication capable.
Integrated Solutions: Integrated systems that optimally combine pneumatic, electric, and electronic components.
Pneumatic Automation Applications in Mill Processes
Raw Material Acceptance and Pre-processing Automation
Pneumatic solutions in the first operations of raw materials entering the facility:
Pneumatic Unloading Systems: Vacuum systems that quickly and cleanly unload raw materials from trucks, railcars, and ships.
Automatic Sampling: Pneumatic systems that automatically take representative samples to evaluate the quality of incoming raw materials.
Pneumatic Cleaning: Effective cleaning operations through pneumatic control of destoners, sieves, and magnetic separators.
Grain Conditioning: Precise management of humidity and temperature parameters through pneumatic control during the conditioning process.
Moisture Control Systems: Pneumatic moisture control systems that continuously monitor raw material moisture levels and bring them to optimum levels.
Pneumatic systems for operations at the heart of the mill process:
Roll Feed Automation: Pneumatic control systems that ensure equal and continuous feeding of raw materials to rolls.
Product Conveying and Distribution: Pneumatic conveying that provides controlled distribution of products in the grinding process to different equipment.
Automatic Sifting Control: Pneumatic systems that monitor and optimize sieve performance and prevent blockages.
Flour Mixing and Blending: Pneumatic mixing systems that enable precise proportional mixing of different flour types and additives.
Bran and By-product Separation: Pneumatic control solutions for efficient separation of different product fractions.
Storage and Silo Automation Systems
Smart pneumatic solutions for intermediate and final product storage:
Pneumatic Level Measurement: Pneumatic systems that precisely measure product levels in silos, based on radar, ultrasonic, or membrane technology.
Automatic Silo Control: Pneumatic control that automates silo filling and emptying processes, providing optimum silo utilization.
Multi-product Management: Integrated pneumatic systems that provide management and traceability of different product types.
Line Cleaning: Pneumatic cleaning systems that automatically clean lines during product changes, preventing contamination.
Silo Ventilation: Ventilation systems that provide optimum temperature and humidity conditions to preserve the quality of stored products.
Pneumatic automation for the final stages of production:
Package Forming: Pneumatically controlled systems for shaping paper or plastic packaging.
Automatic Filling and Weighing: Pneumatic filling and weighing systems that ensure precise amounts of product are filled into packages.
Pneumatic Package Conveying: Pneumatic conveying systems that transfer packages between conveyors, preventing damage.
Vacuum Palletizing: Vacuum technology systems for automatic stacking and palletizing of packages.
Automatic Line Switching: Pneumatic systems that automatically route product flow between different packaging lines.
Pneumatic Automation Systems Design and Integration
Pneumatic System Design Criteria
Design principles for efficient and reliable pneumatic systems:
Capacity Analysis: Optimum capacity and performance calculations according to facility needs.
Pressure and Flow Calculations: Efficient system design with system pressure, air flow, and pressure drop calculations.
Pipe Diameter Optimization: Optimum pipe diameter and line design for energy efficiency and system performance.
Energy Efficiency Planning: System design providing maximum performance with minimum energy consumption.
Safety and Standards: Safe system design compliant with ATEX, FDA, and other industry standards.
Control Systems and Automation Integration
Integration of pneumatic systems into automation infrastructure:
PLC and SCADA Integration: Integration of pneumatic systems into central control and monitoring platforms.
HMI Design: User-friendly interfaces that enable operators to use the system effectively.
Fieldbus Protocols: Communication network setup with industrial protocols such as Profinet, EtherNet/IP, and Modbus.
ERP and MES Integration: Integration of data collected from pneumatic systems into production management systems.
Data Analysis: Software solutions that continuously monitor, analyze, and report pneumatic system performance.
Pneumatic solutions for technological transformation of existing facilities:
Phased Modernization: Phased renovation strategies planned to minimize production interruption.
Hybrid System Integration: Optimal combination of existing and new technologies.
Performance Improvement: Improvements that provide rapid returns through optimization of existing systems.
Data Integration: Data collection from old systems and integration with new systems.
Project Management and Implementation Methodology
Professional approach for successful pneumatic automation projects:
Needs Analysis: Comprehensive analysis of facility needs and optimum solution design.
Detailed Engineering: Comprehensive technical drawings, calculations, and documentation.
Installation Planning: Detailed installation and transition plan for minimum production interruption.
Test Protocols: Comprehensive testing and validation of all system functions.
Personnel Training: Comprehensive training programs for operators, maintenance, and technical personnel.
Operational Efficiency and Performance
Contributions of pneumatic automation systems to business efficiency:
Production Consistency: Consistent and standard production through automation of manual operations.
Material Transfer Optimization: Acceleration of production flow through efficient transport of raw materials and products throughout the facility.
Precise Dosing: Improved product quality through precise proportional mixing of ingredients.
Downtime Minimization: Maximization of production capacity through reduction of unplanned downtime.
Capacity Increase: Increased production speed and capacity through automatic control.
Benefits of quality-focused pneumatic systems:
Precise Process Control: Consistency in product quality through precise control of critical process parameters.
Contamination Reduction: Prevention of product contamination through closed system transport and processing.
Homogeneous Mixing: Achieving perfectly homogeneous products with pneumatic mixing systems.
Traceability: Comprehensive traceability through automatic recording of production parameters.
Recipe Management: Precise recipe control and repeatability for different products.
Cost Savings and ROI
Financial returns of pneumatic automation investments:
Labor Productivity: Reduction in labor costs through automation of manual operations.
Energy Savings: Reduction in energy consumption through efficient pneumatic systems.
Waste Reduction: Reduction in product waste through precise control.
Maintenance Optimization: Savings in maintenance costs through predictive maintenance.
Long-term ROI: Investments that typically amortize themselves within 12-24 months.
Health, safety, and environmental advantages of pneumatic systems:
Operator Safety: Increased workplace safety through automation of dangerous and demanding manual operations.
Dust Explosion Prevention: Minimization of explosion risks through closed system transport and ATEX-compliant equipment.
Clean Production Environment: Clean and healthy working environment through effective dust control and filtration systems.
Product Safety: Compliance with food safety standards through reduced contamination risk.
Ergonomic Working: Ergonomic working conditions through elimination of heavy lifting and manual transport operations.
Tanış A.Ş. Pneumatic Automation Solutions
Our Pneumatic Automation Products for Mill Facilities
Our pneumatic product range developed specifically for the mill sector:
Grain Conveying Systems: High-capacity, energy-efficient pneumatic conveying solutions.
Pneumatic Control Units: Precise pneumatic control systems for flow control and routing.
Dosing Systems: Pneumatic dosing units for precise proportional mixing of raw materials and additives.
Filtration Solutions: High-efficiency, automatic cleaning filter systems.
Smart Sensor Systems: Smart sensor networks that monitor process parameters and provide optimization.
Solutions customized according to your needs:
Custom Design Systems: Pneumatic automation solutions designed according to the specific needs of your facility.
Integrated Facilities: End-to-end pneumatic automation from raw material acceptance to final product shipping.
Modernization Projects: Phased modernization solutions that increase the performance of existing systems.
Capacity Increase: Pneumatic system improvements that increase production capacity with minimum investment.
Energy Efficiency: Projects that minimize energy consumption and reduce operating costs.
Our Engineering and Consulting Services
Engineering support we provide with our expert team:
System Analysis: Evaluation of existing systems and identification of improvement opportunities.
Engineering and Design: Detailed system design, calculations, and technical documentation.
Simulation: Simulation and optimization of system performance with digital twin technology.
Energy Analysis: Energy consumption and efficiency analyses, calculation of savings potential.
Training Programs: Comprehensive training programs for operators, maintenance, and technical personnel.
Continuous support for uninterrupted operation of your systems:
Preventive Maintenance: Ensuring continuity of system performance through regular maintenance programs.
Remote Monitoring: Remote monitoring of systems and proactive support through IoT technologies.
Emergency Response: 24/7 technical support and rapid response services.
Performance Evaluation: Periodic system performance evaluations and optimization recommendations.
Continuous Improvement: System updates and continuous improvement in parallel with technological developments.
As Tanış A.Ş., we take pride in offering advanced pneumatic automation solutions for your mill facilities and being with you on your digital transformation journey. Contact us for free facility evaluation and consultation.