Alexis NoëlProduct Manager Digital Services Milling Solutions

Moving towards predictive maintenance with Temperature &Vibration Management TVM

Challenges in the Operation

3

What are the main challenges of operating a mill?1. Listening to the milling industry, it’s all about delivering to their customers

• The right product

• At the right quality

• At the right quantity

• At the right time

2. With lots of roadblocks on the way

• Breakdowns

• Raw material

• Traceability

• Energy

• People

Challenges in the Operation

4Time

Temperature

Critical area

• Quality/yield impact

• Excessive energyconsumption

• Additional wear

Optimal grinding area

• Highest energy efficiency

• Constant quality

WithoutTVM

WithTVM

*Graph for visualization purposes only

Solution in Maintenance

5

It’s an all-included service!

• Temperature monitoring on the whole length of the roll

• Vibration monitoring

• Proprietary algorithms to detect critical operating

conditions

• All running on Bühler Insights platform

What is TVM?

Solution in Maintenance

6

Service FeaturesHow the service can help you

Automated over-temperaturedetection

Detect over-temperature early tomitigate impact on production.

Automated detection oftemperature imbalancesOptimize your grinding withcustomized threshold.

Temperature & vibrationvisualization

Understand your process atthe blink of an eye.

Alarms & notifications

Get alarms when our algorithmsdetect an optimization potential.

Benchmarking & trends

Benchmarking and trendsare detected in your plants.

New featuresreleased continuously

Maintenance support, rolllifetime calculation, etc.

Product winding indication

Detect product winding onyour rolls in real time so youcan act fast.

Features of TVM

Solution in Maintenance

7

Look and FeelTemperature and Vibration Management

CASE STUDY

8

Can we detect uneven and faster roll wear?

CASE STUDY

9

Actions

• Adapt the rolls to an optimal temperature distribution over

the whole length of the roller

Temperature imbalance side-to-sideImpact

• Uneven granulation over roll length

• Uneven roll wear

• Additional energy consumption

• Throughput loss

High temperature difference between left/right side of the rollcompared to the middle of the roll.

– Not recognized by the operator

CASE STUDY

10

Temperature imbalance middle-to-sideImpact

• Uneven granulation over roll length

• Uneven roll wear

• Additional energy consumption

• Throughput loss

High temperature difference between left/right side of the rollcompared to the middle of the roll.

– Not recognized by the operator

Nearly 100°Cin the middle

Oct 9 changedfeeding gapActions

• Adapt the rollers to an optimal temperature distribution over

the whole length of the roller

• In this case: feeding gap adjustment

• Alternatively: Roll cambering adjustment

CASE STUDY

11

Actions

• Inspect passage for proper product feed and gap alignment

• Inspect the roll pack, including scraper knives

Over-temperature detectionImpact

• Safety risk due to high temperature

• Damage of roll surface / machine

• Uneven granulation over roll length

• Unstable process, dry run possible

• Additional energy consumption

High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operatorTemperature spike on smooth passage

– Not recognized by the operator

12

Can we detect winding/cakeing?

High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator

Temperature spike on smooth passage– Not recognized by the operator

CASE STUDY

13

Actions

• Inspect passage for proper product feed and gap alignment

• Inspect the roll pack, including scraper knives

Winding and cakeing indicationImpact

• Safety risk due to high temperature

• Uneven granulation over roll length

• Additional energy consumption

High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator

Temperature spike on smooth passage– Not recognized by the operator

Over-temperature detection and alarm occurred

– Not recognized by the operator

over-temperaturealarm

CASE STUDY

14

Actions

• Correct scraping knife adjustmentHigh temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator

Temperature spike on smooth passage– Not recognized by the operator

Vibration in suspend(automated detection coming soon)

Critical condition invisible to operator standing in front of themachine but detected through the vibration in suspend

Before

After 2 hoursrunning with a

touchingscraping knife

Impact

• Higher energy consumption

• Refurbishment more frequent leading to

higher maintenance cost

Benefits for a MillingOperation

15

Assumptions300 tpd mill310 days production$0.10 / kWh75 kWh/t (millsection: 50 kWh/t)$5’000/recall (12.5tflour)Miller wage 15$/hour

Detection of criticaloperation condition

Consistent productquality - low energy

Data transparencyPrecise processknow-how

By detectingcritical operationcondition early, likeover-temperature orhigh imbalances, youcan ensure a safe,reliable and predictableoperation.

With TVM, you canmake sure that yourproduct qualityremains constantwhile minimizingenergy consumption,even remotely.

TVM offers thechance for the miller tounderstand the grindingprocess based on data.This is crucial when itcomes to recipe/joboptimization.

TVM providesdetailed temperature &vibration information tocompare your plantsand production lines.