At Boss Automation We Don't Make The Flakers,

We Make The Flakers Better.

Flake Boss 2.0

See Our Systems

Basic Control System

Flake Boss 2.0

 

The World’s Most Advanced Suite of Programing Tools Ever Designed to Automate and Refine Steam-Flaked Grain Quality...

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Flake Management

Flake Boss 2.0

 

This innovative technology will allow for the auto collection and sampling of flaked grain from the both sides of the flaker machine...

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Grain Moisture Systems

Flake Boss 2.0

 

Advanced microwave technology measures the moisture of the incoming grain. Adjustments are then made to the amount of water...

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Flake Boss Packages

Flake Boss 2.0

 

The Flake BOSS 2.0 is the second generation of a revolutionary design that has changed how flaking has been approached for over...

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What makes Flake Boss 2.0 a cut above the rest?

 

The Flake BOSS 2.0 is the second generation of a revolutionary design that has changed how flaking has been approached for over the last 100 years. Our advanced system is a collection of equipment and automation applications designed to provide a superior steam flaked grain. By gathering accurate analytical data and then analyzing this information, we make precise adjustments to the various processes involved in the production of steam flaked grain, eliminating operator error and inconsistency. Our experienced designers and programmers work hard to develop a control system that provides a higher degree of quality in the finished product. Take a look at our package systems below.

30 Years

Boss Automation

 

With over 30 years of Commitment to our customers. We take great Pride into creating quality products and providing outstanding services that will keep us in mind with your next project. With our unparalleled experience in the agricultural field we guarantee an Earnest experience. Whether it be speed of completion, quality of craftsmanship or developing answers to your questions. We will be consistently here to serve you!

Boss Automation Industrial Controls

"We are what we repeatedly do.

Excellence, therefore, is not an act but a habit."

ARISTOTLE

  • Flaker Start Up

    The Old Way

    Operator starts the Flaker by navigating hardwired start/stop buttons. Equipment may or may not be hard wire interlocked with downstream equipment.

    The New Way

    All equipment is automatically started from a centralized Graphical HMI Station that is controlled by the Flake BOSS PLC. The PLC monitors every aspect of the system to make sure that all equipment is ready to run. All ancillary equipment such as hydraulic pumps or flake conveyors are automatically started simultaneously.

  • Steam Cook Control

    The Old Way

    A labor intensive operation begins which consists of the Operator(s) continually monitoring temperature gages located all throughout the Steam Chest, then making adjustments to the cook process with hand operated manual steam control valves.

     

    Due to the reliance on manual operation and attention, anytime the operator is distracted, called away, or otherwise uninvolved in the cook process: wide temperature swings can occur resulting in inconsistencies in the finished product.

    The New Way

    The FlakeBOSS 2.0 automated control system continually monitors the internal temperature of the grain in the Steam Chest with advanced digital temperature monitoring technology- all while giving you a live feed on this data in one central hub. The PLC then incorporates this data into precise PID calculations and makes precise adjustments to levels, so as to provide a very consistent and thorough cooking process. Consistency in this portion of the Steam Flaking process is one of the key factors to optimizing starch availabilities in the finished product, and Flake Boss 2.0 is designed to optimize the process to the nearest degree.

  • Flaking Speed Control

    The Old Way

    The Operator controls the speed of the flaking process by controlling the rotation of the peg feeder. These adjustments are made solely at the operator's discretion and may or may not be based on actual sound “Good Flaking Principles.”

    The New Way

    All changes made to the Flaking Speed are controlled by the FlakeBOSS 2.0 control system and are based on accurate analytical data. This data includes Flaker motor amps, Flaking pressure (actual psi of pressure being exerted between the rolls,) Flake Density, determined by an accurate weighing process.

     

    These analytical inputs are used in a PID formula to calculate and control feeder speed.

  • Preheating

    The Old Way

    1-2 hrs before Flaking startup, the Operator first must manually open the Grain Processing Plant’s Steam Valves- then wait for the steam chest heat get up to the desired temperature. This wastes both the Operator’s and the Grain Mill’s time, setting production back at the very start of the day’s operation.

    The New Way

    At the preprogrammed time that the Mill’s Operator sets, the FlakeBOSS 2.0 Automation system automatically enters into Preheat mode. The PLC will open the Master Steam Safety Valve as well as the appropriate Steam Header Control Valves, while monitoring pressures and checking for malfunctions.

     

    This allows the Steam Chest to completely finish Preheating, even before the Operator arrives at the facility: all while continuously streaming cataloged temperature and pressure read-outs; allowing it to be monitored anywhere on a laptop or mobile device.

     

    Once the Steam Chest has arrived at the desired preset temperature, the control system can either be set to hold in preheat mode, or to automatically cycle into cook mode, where it will begin feeding the Grain into the system.

  • Flake Density Monitoring

    The Old Way

    Operator periodically collects a flake sample from beneath the rolls with a shovel then uses a weight sampling cup to determine the current flake density. The problem with this procedure is that no two operators weigh the sample in exactly the same way. This can result a great variance in the perceived result and doesn't accurately represent true results.

    The New Way

    The FlakeBOSS 2.0 Flake management system automatically pulls a sample from each side of the flaker at a pre-programmed interval. This sample is then accurately weighed in a precise and consistent manner resulting in much tighter process.

  • Flake Density Control

    The Old Way

    The operator uses the results from the flake weighing process to determine if the flake weight or density is within the acceptable limits of the the desired flake weight. If a change needs to be made, the operator manually adjusts the gap between the rolls by mechanically adjusting a fixator device that limits the amount travel of the rolls when closing, thereby adjusting the gap. This can only be through the practice and experience of the operator.

    The New Way

    The FlakeBOSS 2.0 Flake Management system analyzes the accurately weighed sample, then determines if the flake weight or density is within the acceptable limits of the the desired flake weight. If a change is needed, the PLC sends control signals to the automated gap control equipment- which in turn automatically makes changes the size of the roll gap in small incremental amounts.

     

    After each adjustment, a new sample is automatically pulled and analyzed for accuracy and consistency- and then archived for posterity and future reference.

  • Conveyance Interlocking

    The Old Way

    Equipment may or may not be hard wire interlocked with downstream equipment, if not then the potential for factory failure is greatly increased.

    The New Way

    The PLC monitors every aspect of the system to make sure that all equipment is ok to run.

     

    All ancillary equipment such as hydraulic pump or flake conveyance are automatically monitored for run condition. In the event an unexpected shutdown occurs, the program will automatically shutdown the entire system in a controlled manner, and alert the operator of the problem with a variety of methods.

  • Alarm Notification

    The Old Way

    Most older systems do not allow for any notification or warning system, relying on person to person communication in order to address a problem.

     

    The New Way

    The FlakeBOSS 2.0 system is able communicate issues with a factory wide alarm- while also showing operational status information to the operator in a number of different ways.

     

    The system can be set to send notifications to Email, through an SMS Text Messages, and old fashioned flashing lights and buzzers.

  • Equipment Protection

    The Old Way

    Most older systems do not allow for any equipment protection, only through observation are failures able to be caught.

    The New Way

    The PLC monitors every aspect of the system to make sure that all equipment is safe and ready to run.  If any problem occurs in the system at any time, then safety protocols are automatically implemented.

     

    These include:

    • Opening the rolls anytime the feeder shuts down: to prevent dry rolling, or grinding of the corrugations with no product present, which saves money in costly repairs or replacement.
    • Closing the steam valves in the event of extended equipment shutdown.
    • Monitoring the Equipment Amp load, so it can shut-down, open the rolls, and shut off the feeder in the event of the rolls starting to wrap.
  • Analytical Data

    The Old Way

    Most older systems do not allow for any collection of analytical data, anything done manually would have to be observed and cataloged by the operators.

    The New Way

    The FlakeBOSS 2.0 System collects and stores a vast amount of analytical data in a SQL database. This data can then be retrieved and analyzed at a later time by management or nutritionists, to better incorporate informed changes in Flaking or Feeding strategies.

Deakin Electric, Inc

321 South Main Street. Spearman, TX 79081

Toll Free - 1(800) 999-1506 : Phone - (806) 659-5016 : Fax - (806) 659-2822

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  • Flaker Start Up

    The Old Way

    Operator starts the Flaker by navigating hardwired start/stop buttons. Equipment may or may not be hard wire interlocked with downstream equipment.

    The New Way

    All equipment is automatically started from a centralized Graphical HMI Station that is controlled by the Flake BOSS PLC. The PLC monitors every aspect of the system to make sure that all equipment is ready to run. All ancillary equipment such as hydraulic pumps or flake conveyors are automatically started simultaneously.

  • Steam Cook Control

    The Old Way

    A labor intensive operation begins which consists of the Operator(s) continually monitoring temperature gages located all throughout the Steam Chest, then making adjustments to the cook process with hand operated manual steam control valves.

     

    Due to the reliance on manual operation and attention, anytime the operator is distracted, called away, or otherwise uninvolved in the cook process: wide temperature swings can occur resulting in inconsistencies in the finished product.

    The New Way

    The FlakeBOSS 2.0 automated control system continually monitors the internal temperature of the grain in the Steam Chest with advanced digital temperature monitoring technology- all while giving you a live feed on this data in one central hub. The PLC then incorporates this data into precise PID calculations and makes precise adjustments to levels, so as to provide a very consistent and thorough cooking process. Consistency in this portion of the Steam Flaking process is one of the key factors to optimizing starch availabilities in the finished product, and Flake Boss 2.0 is designed to optimize the process to the nearest degree.

  • Flaking Speed Control

    The Old Way

    The Operator controls the speed of the flaking process by controlling the rotation of the peg feeder. These adjustments are made solely at the operator's discretion and may or may not be based on actual sound “Good Flaking Principles.”

    The New Way

    All changes made to the Flaking Speed are controlled by the FlakeBOSS 2.0 control system and are based on accurate analytical data. This data includes Flaker motor amps, Flaking pressure (actual psi of pressure being exerted between the rolls,) Flake Density, determined by an accurate weighing process.

     

    These analytical inputs are used in a PID formula to calculate and control feeder speed.

  • Preheating

    The Old Way

    1-2 hrs before Flaking startup, the Operator first must manually open the Grain Processing Plant’s Steam Valves- then wait for the steam chest heat get up to the desired temperature. This wastes both the Operator’s and the Grain Mill’s time, setting production back at the very start of the day’s operation.

    The New Way

    At the preprogrammed time that the Mill’s Operator sets, the FlakeBOSS 2.0 Automation system automatically enters into Preheat mode. The PLC will open the Master Steam Safety Valve as well as the appropriate Steam Header Control Valves, while monitoring pressures and checking for malfunctions.

     

    This allows the Steam Chest to completely finish Preheating, even before the Operator arrives at the facility: all while continuously streaming cataloged temperature and pressure read-outs; allowing it to be monitored anywhere on a laptop or mobile device.

     

    Once the Steam Chest has arrived at the desired preset temperature, the control system can either be set to hold in preheat mode, or to automatically cycle into cook mode, where it will begin feeding the Grain into the system.

  • Flake Density Control

    The Old Way

    The operator uses the results from the flake weighing process to determine if the flake weight or density is within the acceptable limits of the the desired flake weight. If a change needs to be made, the operator manually adjusts the gap between the rolls by mechanically adjusting a fixator device that limits the amount travel of the rolls when closing, thereby adjusting the gap. This can only be through the practice and experience of the operator.

    The New Way

    The FlakeBOSS 2.0 Flake Management system analyzes the accurately weighed sample, then determines if the flake weight or density is within the acceptable limits of the the desired flake weight. If a change is needed, the PLC sends control signals to the automated gap control equipment- which in turn automatically makes changes the size of the roll gap in small incremental amounts.

     

    After each adjustment, a new sample is automatically pulled and analyzed for accuracy and consistency- and then archived for posterity and future reference.

  • Flake Density Monitoring

    The Old Way

    Operator periodically collects a flake sample from beneath the rolls with a shovel then uses a weight sampling cup to determine the current flake density. The problem with this procedure is that no two operators weigh the sample in exactly the same way. This can result a great variance in the perceived result and doesn't accurately represent true results.

    The New Way

    The FlakeBOSS 2.0 Flake management system automatically pulls a sample from each side of the flaker at a pre-programmed interval. This sample is then accurately weighed in a precise and consistent manner resulting in much tighter process.

  • Conveyance Interlocking

    The Old Way

    Equipment may or may not be hard wire interlocked with downstream equipment, if not then the potential for factory failure is greatly increased.

    The New Way

    The PLC monitors every aspect of the system to make sure that all equipment is ok to run.

     

    All ancillary equipment such as hydraulic pump or flake conveyance are automatically monitored for run condition. In the event an unexpected shutdown occurs, the program will automatically shutdown the entire system in a controlled manner, and alert the operator of the problem with a variety of methods.

  • Alarm Notification

    The Old Way

    Most older systems do not allow for any notification or warning system, relying on person to person communication in order to address a problem.

     

    The New Way

    The FlakeBOSS 2.0 system is able communicate issues with a factory wide alarm- while also showing operational status information to the operator in a number of different ways.

     

    The system can be set to send notifications to Email, through an SMS Text Messages, and old fashioned flashing lights and buzzers.

  • Equipment Protection

    The Old Way

    Most older systems do not allow for any equipment protection, only through observation are failures able to be caught.

     

     

    The New Way

    The PLC monitors every aspect of the system to make sure that all equipment is safe and ready to run.  If any problem occurs in the system at any time, then safety protocols are automatically implemented.

     

    These include:

    • Opening the rolls anytime the feeder shuts down: to prevent dry rolling, or grinding of the corrugations with no product present, which saves money in costly repairs or replacement.
    • Closing the steam valves in the event of extended equipment shutdown.
    • Monitoring the Equipment Amp load, so it can shut-down, open the rolls, and shut off the feeder in the event of the rolls starting to wrap.
  • Analytical Data

    The Old Way

    Most older systems do not allow for any collection of analytical data, anything done manually would have to be observed and cataloged by the operators.

    The New Way

    The FlakeBOSS 2.0 System collects and stores a vast amount of analytical data in a SQL database. This data can then be retrieved and analyzed at a later time by management or nutritionists, to better incorporate informed changes in Flaking or Feeding strategies.