Yield Scale
Yield Scale: Precise Measurement and Control of Mill Efficiency
Economic sustainability and competitive advantage in the modern milling sector depend on obtaining optimum flour yield. The Yield Scale developed by Tanış A.Ş. enables you to maximize production efficiency by precisely measuring flour extraction rate in mill processes. This device, equipped with advanced weighing technology and smart analysis systems, allows you to optimize your mill operations with scientific data.
Yield Scale is an advanced technology device that precisely measures the ratio between wheat input and flour amount obtained in the mill process. This ratio is known as “extraction rate” or “yield” in the milling sector and is the most important indicator of mill performance.
Flour extraction rate and yield concept is the percentage expression of flour amount obtained from processed wheat. For example, when 78 kg of flour is obtained from 100 kg of wheat, the yield is expressed as 78%. This rate varies depending on the wheat variety used, performance of mill equipment, and process settings.
The importance of yield measurement in mill process stems from its direct reflection on financial performance. Even small increases in yield provide significant economic gains in high-capacity mills. For example, a 1% increase in yield in a mill processing 100 tons of wheat daily means approximately 300 tons of additional flour production annually.
There is a direct relationship between precise measurement and process optimization. Yield Scale enables mill operators to adjust process parameters at ideal levels by providing real-time and accurate measurements. This way, both yield is maximized and product quality is consistently maintained.
Yield Scale has an integrated structure combining precise weighing technology and advanced data analysis systems. Its basic components include wheat weighing unit, flour weighing unit, data processing module, and user interface.
Precise weighing technology is realized using high-accuracy load cells. These sensors continuously measure the amounts of wheat entering the mill and flour exiting. Measurement errors are reduced below 0.1%, providing performance above industrial standards.
Comparative measurement of wheat and flour amounts is performed in real-time. The system precisely measures the amount of wheat entering the mill in a specific time interval and the amount of flour obtained from the same process. The ratio between these two values is calculated to determine instantaneous yield value.
Data processing and calculation algorithm processes measured values and converts them to meaningful results. Advanced software performs yield calculation from raw weighing data while also considering process variables. Thus, consistent results unaffected by temporary fluctuations are obtained.
Calibration system and accuracy control ensure long-term preservation of measurement precision. The system performs automatic calibration checks and informs the operator of calibration needs when necessary by giving warnings. Additionally, it offers integrated tools for periodic verification tests.
Load cells and precise sensor technology used in Yield Scale include the most advanced applications of industrial weighing systems. Stainless steel load cells are minimally affected by temperature changes and electromagnetic effects.
Weight measurement precision and tolerance values are above international standards. The system can measure with precision of 0.02% of its capacity. Thanks to this high precision, maximum accuracy is achieved in yield calculation.
Vibration compensation and external effect filtration provide reliable measurement even under harsh conditions of mill environment. Digital signal processing technology filters environmental noise and vibrations from mill equipment, obtaining clean weighing signals.
Temperature and humidity compensation features provide consistent measurement performance under different environmental conditions. Special algorithms and sensors automatically correct the effects of environmental condition changes on measurement results. This way, the same precision measurement is performed regardless of summer-winter or day-night differences.
Technical Specifications and Performance Parameters
Tanış Yield Scale is offered in various models suitable for mills of different capacities. Basic technical specifications are as follows:
| Model | Capacity (tons/day) | Accuracy | Power Requirement | Communication | Display |
|---|---|---|---|---|---|
| TMRK-350 | 50 | ±0.1% | 220V AC, 50Hz | RS485, Ethernet | 5″ Touch |
| TMRK-420 | 90-150 | ±0.1% | 220V AC, 50Hz | RS485, Ethernet | 7″ Touch |
| TMRK-520 | 150-300 | ±0.1% | 220V AC, 50Hz | RS485, Ethernet, USB | 10″ Touch |
| TMRK-750 | 300-600 | ±0.05% | 220V AC, 50Hz | RS485, Ethernet, USB, Wifi | 12″ Touch |
| TMRK-1000 | 600+ | ±0.05% | 220V AC, 50Hz | RS485, Ethernet, USB, Wifi | 15″ Touch |
All our models have the following standard features:
- Stainless steel body and load cells
- IP65 protection class
- Multi-language support
- Real-time data analysis
- Historical data storage and reporting
- Alarm and warning system
- Remote access capability
- Industrial operating temperature range (-10°C to +50°C)
Measurement capacity and weighing range are optimized by selecting appropriate model according to mill size. Each model can perform accurate measurement in the range of 5-100% of its nominal capacity.
Accuracy and repeatability values offer performance above industry standards. While measurement accuracy varies between ±0.05% and ±0.1%, repeatability value is 0.03%. This precision provides maximum reliability in yield calculations.
Data update rate and response time are optimized for real-time monitoring. The system detects instantaneous changes rapidly by making 10 measurements per second. Data update rate is user-adjustable and can be optimized according to process needs.
Model Options and Capacity Alternatives
Tanış Yield Scale is offered in various models suitable for the needs of mills of different capacities. While RK-100 series is ideal for small and medium-scale mills, RK-1000 series is designed for large industrial facilities.
While suitable models are offered for various facility sizes, assembly and installation options also vary. Compact design and flexible connection options are offered for easy integration into existing facilities.
Configuration alternatives are available for special requirements. Measurement systems optimized for different flour types and grain varieties, special reporting formats, or extended data analysis packages can be offered upon request.
Extraction Rate Calculation and Importance
The mathematical basis of yield calculation is based on the relationship between the amount of wheat processed and the amount of flour obtained. This calculation is expressed with the following formula:
Extraction Rate (%) = (Flour Amount Obtained / Wheat Amount Processed) × 100
The effect of extraction rate on milling economics is very significant. Every 1% increase in yield directly reflects on profit margin. In a mill with 200 tons daily capacity, a 1% increase in yield means approximately 600 tons of additional flour production annually, which creates significant economic value.
Determining optimum extraction rate requires balance between both economic efficiency and product quality. Very high extraction rate target can cause decrease in flour quality. Yield Scale helps maintain this balance by providing real-time data to determine ideal operating point.
Expected yield values for different flour types are as follows:
- White bread flour: 72-78%
- Whole wheat flour: 85-95%
- Pasta and pastry flour: 68-72%
- Premium baklava flour: 60-65%
Effect of mill settings on yield is very important. Factors such as distance between roller pairs, sieve efficiency, tempering time directly affect yield. Yield Scale offers optimization opportunity by measuring effects of these settings in real-time.
Data Management and Reporting Features
Real-time data monitoring and display is one of the basic features offered by Yield Scale. Through color touch screen, instantaneous yield value, wheat and flour flow amounts, daily total values, and deviations from target can be displayed.
Historical data recording and trend analysis offer powerful tools for long-term performance evaluation. The system automatically records hourly, daily, weekly, and monthly yield data. This data can be displayed graphically and trend analyses can be performed.
Customizable reports and data outputs meet various management needs. Various formats such as shift reports, raw material change analyses, yield reports correlated with quality parameters can be used. Reports can be exported in PDF, Excel, or CSV formats.
Statistical analysis and performance evaluation tools can be used for deeper analysis of data. Statistical functions such as average, standard deviation, minimum/maximum values, trend analyses, and target deviation calculations are available.
Process Control and Optimization
Real-time yield monitoring with process adjustment offers the opportunity to continuously optimize mill performance. Operators can make necessary interventions timely by instantly seeing changes in yield values.
Effect of mill parameters on yield can be analyzed using Yield Scale data. Effects of changes in parameters such as roller settings, sifting efficiency, tempering time, and moisture ratio on yield can be monitored to determine optimum operating conditions.
Determining and maintaining ideal operating point becomes possible through continuous yield monitoring. The system can alarm when there are deviations from target yield value and offer suggestions for corrective actions.
Optimization under changing grain quality conditions can be performed more effectively with data provided by Yield Scale. Yield differences due to different wheat batches or seasonal changes can be tracked, and process parameters can be adjusted dynamically.
Automation and System Integration
Integration with existing mill control systems is one of the important advantages offered by Yield Scale. Thanks to standard industrial communication protocols, smooth connection can be established with most automation systems.
Connection to SCADA and PLC systems provides integrated process control throughout the facility. Yield data can be transferred to central automation system, correlated with other process parameters, and comprehensive process optimization can be performed.
Data communication protocols and network connections offer flexible integration opportunity. Standard industrial protocols such as Modbus, Profibus, Ethernet/IP are supported. Additionally, OPC UA compatibility is also available.
Remote access and monitoring capabilities meet modern business management needs. Thanks to web-based interface and mobile application support, mill performance can be monitored from office or while on the move.
Economic Advantages and Investment Value
Economic return achieved through yield optimization is the most important advantage of Yield Scale investment. Yield increase of 0.5-1% can be achieved in an average mill. This increase means tens of thousands of dollars of additional revenue annually even in a medium-scale mill.
Reducing operating costs and increasing efficiency provides competitive advantage. Thanks to optimum process control, both raw material use is optimized and energy consumption is reduced. Additionally, total cost advantage is achieved by reducing waste rates.
Product quality control and standardization are critically important for customer satisfaction and brand value. Yield Scale helps achieve consistent product quality by ensuring extraction rate is balanced with quality parameters.
Return on investment analysis reveals the economic value of Yield Scale. In an average mill, thanks to yield increase and cost optimization achieved, investment can amortize itself in a short period of 6-12 months.
Frequently Asked Questions
What are the factors affecting Yield Scale accuracy?
Measurement accuracy is directly related to sensor quality, calibration status, mounting conditions, vibration level, and material flow regularity. Tanış Yield Scale provides maximum accuracy with its design that optimizes these factors and advanced compensation algorithms.
Can I easily integrate it into my existing mill?
Yes, thanks to its modular design, Yield Scale can be integrated into most existing mills with minimal modification. Tanış technical team guarantees seamless transition process by providing facility-specific integration plan and installation support.
How often should calibration be performed?
Periodic calibration every 6 months is recommended under standard operating conditions. 3-monthly controls are advised for intensive use or applications requiring high precision. The system automatically monitors calibration status and warns the user when necessary.
How is yield calculation affected in different wheat types?
Different wheat types (hard, soft, durum wheat, etc.) naturally have different extraction potential. Yield Scale offers the opportunity to adjust target values according to wheat type and perform comparative analysis, thus obtaining optimum performance for each wheat type.
Does production stop if system fails?
No, Yield Scale is a monitoring and optimization tool, not in the critical flow path of mill process. In case of system failure, the mill continues to operate, only yield monitoring and optimization functions are temporarily disabled.