Advanced Hammer Mill Technology

*Capacity values may vary according to the type of grain processed and grinding fineness.

All models have the following standard technical specifications:

• Grinding precision: Adjustable in the range of 0.5-10 mm
• Pneumatic pressure range: 0.5-8 bar
• Maximum operating speed: 3600 rpm
• Bidirectional operation capability
• Digital control panel
• Industry 4.0 compatible communication interface
• Fully automatic lubrication system

Energy Efficiency and Operational Advantages

Hammer Mill also sets a new standard in the industry in terms of energy efficiency:

• Optimized Motor Power: High-efficiency motors specially selected for each model minimize energy consumption.

• Smart Start-up System: Gradual start-up technology prevents high energy consumption at start-up.

• Load-based Energy Optimization: Automatically adjusts energy consumption according to real-time load measurement during grinding process.

• Efficient Mechanical Transmission: High-quality bearings and transmission elements minimize friction losses.

Operational advantages provided:

• Fast Installation: Easy integration and fast installation to 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

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

• High-Quality Materials: Wear-resistant special alloy steel hammer heads.

• Robust Body Construction: Heavy-duty steel body that dampens vibrations.

• Advanced Surface Treatments: Special hardening processes applied to hammer heads provide long-term precise grinding performance.

• Protective Elements: Effective sealing systems that prevent dust and moisture from reaching sensitive components.

• Proactive Maintenance Monitoring: Integrated sensor systems that detect potential problems early.

Hammer Mill stands out as a technology that shapes the future of the milling industry with these superior features and advantages. This system, developed with Tanış A.Ş.’s over 60 years of industry experience and engineering knowledge, is an excellent response to the increasing quality and efficiency demands of modern flour mills.

Technical Specifications and Performance

Hammer 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 technical structure and performance values of the system.

Detailed Technical Specifications

General Specifications:

Mechanical Specifications:

• Hammer Heads: Manufactured from high-carbon, special alloy steel, heat-treated to 62-64 HRC hardness

• Screen System: Different screen hole diameter 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 rotor system (optional)

Pneumatic System Specifications:

• 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

Electronic 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 of operation parameters
• Remote Access: Technical support and updates via VPN
• Alarm System: Audio and visual warning system, SMS/email notification (optional)

Rotor Diameter and Screen Options

Hammer Mill is offered with various size options according to different capacity requirements:

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

Motor Power and Energy Consumption

Hammer Mill systems are equipped with high-efficiency electric motors. Motor powers and energy consumption values by model:

*Energy consumption values are hourly average values at full load. Actual consumption may vary according to the type of grain ground and grinding fineness.

With optionally offered IE4 Super Premium Efficiency class motors, an additional 3-5% energy saving can be achieved.

Grinding Capacity (tons/24 hours)

The grinding capacity of Hammer Mill varies depending on the 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 may affect capacity values.

Precise Adjustment Features

One of the most important features of Hammer Mill is the precise adjustment capabilities it offers:

• Screen Range Adjustment: Adjustable with 0.5-10 mm precision
• Pneumatic Pressure Control: Precise pressure control system adjustable in 0.1 bar increments
• Digital Position Sensors: High-precision sensors that continuously monitor hammer 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 1800-3600 rpm with optional frequency inverter

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

Quality Flour Production with Hammer Mill

Effect on Flour Quality

Hammer Mill optimizes many factors that play a decisive role in flour quality, making high-quality flour production possible:

• Homogeneous Particle Size: Thanks to the equal pressure distribution provided by the pneumatic system, homogeneous particle size is achieved throughout the entire hammer system.

• Minimum Starch Damage: Precisely adjustable pneumatic pressure optimizes starch damage, enhancing 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 the process, ensuring preservation of flour’s natural properties.

Suitability for Different Grain Types

Hammer Mill provides ideal grinding conditions for various grain types thanks to its wide pressure adjustment range and interchangeable screen system:

• Wheat: Optimized grinding parameters for each of hard, semi-hard, and soft wheat varieties.

• Corn: Ideal pressure control system for breaking hard corn kernels and degermination (embryo separation) processes.

• Barley: Precisely adjustable screen system 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

Hammer Mill provides significant improvements in extraction rate and yield values thanks to optimized grinding parameters:

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

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

Micron Precision and Homogeneous Grinding

Hammer Mill offers full control capability at the micron precision required for different grinding stages:

• Coarse Breaking Stages: 2000-5000 microns
• Medium Breaking Stages: 1000-2000 microns
• Fine Grinding Stages: 500-1000 microns
• Final Grinding Stages: 100-500 microns

The system provides homogeneous grinding at the determined micron level, increasing the efficiency of subsequent sieving and separation processes. Standardization in particle size distribution ensures consistency in flour’s rheological properties, enhancing final product quality.

Industrial Applications and Usage Areas

Hammer Mill is designed to perform at high levels in different segments and applications of the milling industry. The ability to be used for different purposes in facilities of various scales makes this system an indispensable equipment in the industry.

Large-Scale Flour Mills

Large-scale flour mills with daily capacity of 200 tons and above benefit maximally from the advanced technology features offered by Hammer Mill:

• High Capacity Requirements: HM-1250 and HM-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 into the facility’s central automation system.

• Quality Standardization: Quality standardization, which is important in large-scale facilities, is maintained without variation from shift to shift thanks to the recipe management system.

• Energy Efficiency: Energy costs are critically important in high-volume production. Hammer Mill’s energy optimization features ensure operating expenses are kept under control.

• Multi-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 Hammer Mill’s flexibility and efficiency features:

• Adaptable Capacity: HM-800 and HM-1000 models offer ideal capacity and cost balance for medium-scale mills.

• Fast Product Changeover: Responds to product variety demands frequently encountered in medium-scale facilities with easily adjustable parameters and recipe management system.

• Easy Modernization: In modernization projects of existing facilities, Hammer Mill’s modular structure provides easy integration.

• Optimum Operating Cost: Operating costs, which are critically important for medium-scale enterprises, are optimized thanks to efficient operating principles.

• Future-oriented Investment: For facilities with capacity expansion plans, it offers a flexible solution that can adapt to future needs.

Special Purpose Grinding Facilities

Hammer 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 the 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: Ideal training equipment for practical application of grinding principles in institutions providing milling education.

Role in Integrated Mill Systems

Hammer 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 in harmony with tempering processes by optimizing grinding pressure according to grain moisture content.

• Communication with Sieving Systems: Increases system efficiency by adjusting grinding parameters based on feedback from sieving 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 into central control systems that coordinate all processes in the facility.

Installation, Maintenance and Service

Easy Installation Features

Hammer Mill has features designed for fast and trouble-free installation:

• Single Unit System: Main unit is shipped as a single piece, requiring minimum assembly on site.

• Standard Connection Points: Input-output connections complying with international standards provide easy integration into existing systems.

• Infrastructure Suitable for Ready Installation: Design suitable for ready installation for electrical, pneumatic, and data connections.

• Self-Level Footed System: Adjustable feet that tolerate floor irregularities.

• Comprehensive Installation Guide: 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 Hammer Mill into your facilities. A typical installation process is completed within 1-3 days depending on size.

Maintenance Requirements and Periodic Inspections

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

Daily Inspections:

• Control of hammer pressure values
• Control of general operating sound
• Control of screen system indicator
• Control of pneumatic system pressure indicator

Weekly Inspections:

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

Monthly Inspections:

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

6-Monthly Maintenance:

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

Under maintenance contracts offered by Tanış A.Ş., these inspections are regularly performed by expert technicians.

Spare Parts and Service Services

We offer comprehensive spare parts and service support for Hammer Mill:

• 24-Hour Spare Parts Supply Guarantee: 24-hour shipment 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 Response: Service response 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 reports and recommendations after each service operation.

Operator Training and Support

We offer comprehensive training and support programs for the most efficient use of Hammer 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 knowledge refreshing purposes.

• Technical Support Line: 7/24 accessible technical support line.

• Online Training Platform: Keeping knowledge and skills up-to-date 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 Hammer Mill always operates at maximum performance in your facilities. Tanış A.Ş.’s 60 years of industry experience and widespread service network ensure the uninterrupted continuation of your mill operations.

Data Showing Contribution to Efficiency

The contributions of Hammer Mill to mill operations have been measured with various performance indicators:

Production Efficiency Improvements:

*Values obtained from real customer data compared to traditional mechanical hammer mills.

Improvements in Quality Parameters:

• Particle Size Distribution: 30% more consistent distribution
• Starch Damage Control: 25% more precise control
• Ash Content Variation: 65% reduction in inter-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 Hammer Mill system:

Why Should Hammer Mill Be Preferred?

Competitive Advantages

Key advantages that distinguish Hammer Mill from competitors:

• Full Industry 4.0 Compatibility: New standard in mill automation with advanced digital integration features.

• Hammer Surface Monitoring Technology: Smart sensor system that continuously monitors hammer 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 that offers real-time energy consumption monitoring and optimization recommendations.

Long-term Benefit Analysis

Long-term benefits of investing in Hammer Mill:

• Technological Infrastructure Guarantee: Technological support and update guarantee for a minimum of 10 years.

• Adaptation Capability: Flexible structure that adapts to changing market conditions and product diversity.

• Sustainability: Environmentally friendly technology that provides energy efficiency and resource optimization.

• Operating Cost Advantage: Low operating cost throughout the product life cycle.

• High Second-hand Value: High second-hand value of Tanış equipment in the market provides advantages in future renewal projects.

Tanış A.Ş. Guarantee and Expertise

When you choose Hammer 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 of 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-oriented Approach: Flexible approach that develops special solutions for each customer’s specific needs.

Frequently Asked Questions

Technical Questions

What are the main advantages of Hammer Mill system compared to traditional mechanical or hydraulic hammer mills?

Hammer 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 mechanical systems experience spring fatigue and hydraulic systems show temperature-dependent performance variations, the pneumatic system is free from these disadvantages. Additionally, pneumatic technology offers a cleaner, easier-to-maintain, and higher energy-efficient solution.

Can the same hammer mill unit be used for different grain types?

Yes, thanks to Hammer Mill’s wide adjustment range and interchangeable screen system, 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 screen range, pressure, and speed. For some special applications, screen systems 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?

Hammer Mill shows optimum performance with compressed air at 6-8 bar pressure, [1:4:1] class 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?

Hammer 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 its 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 operating unaffected by short-term outages.

How often should hammer heads be replaced or renewed?

The life of hammer heads depends on factors such as the type and quality of grain processed, daily operating hours, and screen system. On average, high-quality Hammer Mill hammer heads can be used for 3-5 years under standard operating conditions. The system can provide advance notice of renewal time thanks to sensors that monitor wear on hammer surfaces. Hammer surface renewal is performed by Tanış A.Ş.’s expert teams, preserving original surface pattern and hardness. This process typically costs 40-50% of the original hammer cost.

Maintenance and Operation Questions

What is the recommended maintenance frequency for Hammer Mill?

Although the system requires less maintenance compared to traditional hammer mills, certain periodic inspections are recommended for optimum performance. We recommend daily simple visual inspections, weekly general condition inspections, monthly sensor and calibration inspections, and 6-monthly comprehensive maintenance program. Under maintenance contracts offered by Tanış A.Ş., these inspections are regularly performed and detailed maintenance reports are provided. Regular maintenance extends system life while minimizing unexpected breakdown 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 usage, recipe management, daily inspections 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. Retraining 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 facility, 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 Hammer Mill?

Hammer Mill is provided 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 use 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 in overseas locations. For emergency situations, our remote technical support service via VPN connection can be activated immediately. Service costs are free for warranty-covered failures. Standard service rates apply for out-of-warranty service support. Special discounted service rates are offered for customers with regular maintenance contracts. Service contract includes advantages such as planned maintenance visits, preventive maintenance services, and priority response rights.

How are software updates performed and are these updates paid?

Hammer 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?

Hammer Mill is designed with various measures to minimize breakdown 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.

Conclusion and Contact

Hammer Mill is one of the most innovative solutions in modern milling technology. With its precise pneumatic pressure control, digital operation management, and Industry 4.0 compatible design, it offers unique advantages to mill operations.

Developed with Tanış A.Ş.’s 60 years of mill equipment manufacturing experience and continuous R&D studies, Hammer Mill provides optimum efficiency and quality in wheat, corn, and barley processing facilities.

In Turkey, where 3% of global wheat production takes place, this domestic technology developed with our own engineering power serves our customers in more than 40 countries worldwide.

To get more detailed information about Hammer Mill, receive quotes for solutions suitable for your specific needs, or see our demo systems, you can contact us.