About Flake Boss 2.0

 

Chris Deakin, demonstrating the 'old way' of measuring flake weight to determine the moisture content: Preheating

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.

 

Steam Cook Control

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.

 

Flaker Startup

All equipment is automatically started from a centralized Graphical HMI Station that is controlled by the FlakeBOSS 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.

 

Flaking Speed Control

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.

 

Flake Density Monitoring

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 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 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 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 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 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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About Flake Boss 2.0

 

Chris Deakin, demonstrating the 'old way' of measuring flake weight to determine the moisture content: Preheating

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.

 

Steam Cook Control

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.

 

Flaker Startup

All equipment is automatically started from a centralized Graphical HMI Station that is controlled by the FlakeBOSS 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.

 

Flaking Speed Control

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.

 

Flake Density Monitoring

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 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 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 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 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 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.