PRODUCT CATALOGUE 2015 grain drying and storage technology STELA-LAXHUBER GEbR. RUBERG BROCK BIN SKANDIA ELEVATOR JE-MA PFEUFFER HUTCHINSON
CONTENT Our Philosophy 6 Our Story 8 Present Days 10 Export 12 Our Trademarks 14 PAWLICA Trademark 16 Stationary Dryers 20 Mobile Dryers 28 Industrial Dryers 30 Pre-cleaners 34 Cleaners 36 BIN Silos 38 BROCK Silos 42 Conveyors 52 Hoppers 58 Automatic Control 62 Dust Separation 66 Laboratory Equipment 70 References 78 GRAIN DRYING AND STORAGE TECHNOLOGY
OUR PHILOSOPHY Delivery of high quality technology and service has always been the main goal of the PAWLICA company. During the past sixteen years we have met a number of manufacturers and suppliers and we have made business only with the best ones from Europe and the USA. PAWLICA trademark has become a symbol of quality and reliable post-harvest lines and storage systems for both the farmers and industrial businesses. Customer satisfaction is our top priority. We currently supply the market with modern technology for grain storage provided by certified foreign partners who offer specialized products of the highest quality. For many years we have been representing the German manufacturer of STELA dryers, the American manufacturer of BROCK silos, the Polish exporting producer of BIN silos and the German manufacturer GEBR. RUBERG supplying sophisticated pre-cleaners and cleaners. We also offer transport technology provided by two Scandinavian producers SKANDIA and JE-MA. The US HUTCHINSON Grain Pump technology has been a very popular conveyor system of recent years. For many years we have been also representing PFEUFFER, a German manufacturer of laboratory equipment, whose instruments saw the beginning of our business and are still a great advertisement for us with farmers and food producers. Since my father founded a small family business sixteen years ago, we have become a leading supplier of technology for post-harvest grain treatment in the Czech Republic. Our established reputation and professional approach to projects brought us business as the suppliers and customers were satisfied with the quality of services and products that our company provided. Today, I would like to follow our company s tradition and cherish its values. Together with my colleagues I would like to continue to provide our customers with individual and professional approach to the post-harvest lines solutions, to supply the best and the latest technology while providing professional and fast maintenance services. I am also determined to meet the challenge of maintaining the family atmosphere of the company, which is constantly expanding, even at an international level. I am also determined to do my best so that the Pawlica Ltd. becomes an independent leader in the Central-Eastern Europe. I would like to thank all my colleagues and business partners for helping me meet these objectives. Ing. Petr Pawlica, MBA 6 7
OUR STORY PAWLICA Ltd. was established in 1998 when its founder, Ing. Rudolf Pawlica, PhD., decided to leave his career in the Research Institute of Agricultural Engineering in Prague Řepy and started a business. From the very beginning his company supplied the Czech market with the post-harvest grain treatment technology. The post-harvest technology seems to have been Rudolf Pawlica s destiny. He was a construction and spiritual father of the Strážov dryers, 600 of which were installed in the Czech and Slovak Republic in the course of his thirty-year-long career with the Research Institute. During that period he came by numerous technical findings and impulses, which were beneficial to his business and introduced him, among other things, to the German manufacturer of STELA dryers, which have been one of the company s business pillars since. Rudolf Pawlica joined the research institute after graduating from university. He devoted his research to the post-harvest grain treatment and worked part-time as a technical advisor of a company producing grain dryers. He then began to develop business cooperation with STELA. After the Velvet revolution in 1989 he was looking for ways of making a living for himself and his family. Knowing how important for agriculture grain moisture meters are, he decided to sell them. A friend in Germany recommended the PFEUFFER which has always been a synonym for high quality moisture meters. The company has been representing this brand since then. Rudolf Pawlica used family savings to buy the first moisture meters, so that he could start the business. In the first year, he sold only a few pieces, but the year after it was already forty and the third year around a hundred. The business succeeded. All the while, Rudolf Pawlica kept working at the research institute. In 1998 he founded a Ltd. company bearing his name and returned to grain drying. He founded PAWLICA Ltd. together with his assistant from the Research Institute Adam Černý and several other people. Later on when the production of dryers in Strážov came to an end he took over the representation of STELA. The company built its first STELA dryer in 1995 in Šatov. Due to large popularity of corn and rapeseed, the drying business flourished in the following years and PAWLICA Ltd. has become the leader in its field. Subsequently the company added to its portfolio other brands of reputable foreign manufacturers, who have become its long-term reliable partners. 8 9
PRESENT DAYS Our company has been supplying farmers in the Czech Republic with high quality technology for drying, cleaning and storage of not only grain but also other commodities. We know very well how important the post-harvest treatment is for farmers. It allows them to increase the value of the produce and then sell it with a higher profit. Therefore, we specialize in the sale of such technology, which is grain-friendly, but also very reliable and efficient. Our company does not only specialize in turnkey postharvest lines, but we also refurbish existing lines. We prepare project proposal and design, deliver technology including machinery and electrical assembly as well as an automatic control system set up and finally, we launch the line. We always provide staff training and a test run. Warranty and post-warranty customer service provision is of course included. When designing post-harvest lines and grain storage systems we rely on rich experience of our specialists. We offer the best machine technology solutions to post-harvest lines after a dialogue with the customer. We rely on first-rate foreign technology regarding vital machinery parts and on local technology regarding the ordinary equipment. As we carefully select our manufacturers and cooperate with them in long-term, we are able to deliver individual machinery items as well as entire investment units. For the same reason we are also able to supply technologies adapted to our conditions. Long-lasting relationships with our partners also have a major positive impact on the service and maintenance of the supplied equipment. When carrying out assembly work and project implementation, we confide in work of our partner installation and maintenance companies. We have not lost touch with research and development either. We are currently working on projects with the Mendel University in Brno and the Research Institute of Agricultural Engineering in Prague-Ruzyně. We support environmentally-friendly energy resources and we are a member of the Czech Biomass Association (CZ BIOM). In addition, we are certified to install biomass boilers by Verner company. The seat of PAWLICA Ltd. is located on Drnovská street in Prague 6-Ruzyně. The new headquarters, which includes a spare parts warehouse, was built here a few years ago. Significant activities of the company in eastern Bohemia and the Polabí region made us open a new branch in Opočno, in the premises of AT Com Ltd., which joined our maintenance and assembly centres in the country a few years ago. In the past sixteen years, project managers and project engineers trained by Ing. Rudolf Pawlica, PhD. have built 246 dryers and 600,000 tons of grain and other commodities have been stored in steel galvanized grain storage bins. 10 11
EXPORT In recent years PAWLICA Ltd. has increasingly developed its international activities. The Czech market is not large, thus we seek to find customers for our technology in other countries. Besides the Slovak Republic, where we have had our representation for a long time, we also extended our business to Poland. Polish farmers are highly interested in high-quality post-harvest technology, and therefore, the company has had a significant success there. Two years ago we opened a new branch in Wroclaw, which is run by the coowner Ing. Slawomir Zembrzycki. During the first successful season sixteen STELA dryers were installed, including the latest BiTurbo dryer with two-phase air heating, four GEBR. RUBERG cleaners, and a complete reconstruction of post-harvest line in GR Bojanowo was completed. Currently, other projects for construction of dryers and storage halls with storage bins by BROCK, BIN and MFS have been scheduled. In 2013, PAWLICA Ltd. entered the Slovenian market. Here, under the brand of STELA Engineering GmbH., which is shared by PAWLICA Ltd. and STELA LAX- HUBER GmbH, we implemented a project for agrofood group Panvita near the city of Maribor. Besides the STELA BiTurbo corn dryer (performance of 50 t/h) we have also delivered the GEBR. RUBERG 200 RUV pre-cleaner and Skandia transport systems. All are explosion-proof, ATEX certified models and have a dust limit of maximum 10 mg/m3. At the same time a refurbishment of existing storage bins have been carried out there. The brand of STELA Engineering GmbH will keep on being part of shared projects with the STELA LAXHUBER GmbH company in eastern Europe. There are of course other foreign activities of PAWLICA Ltd. Further projects regarding post-harvest lines are to be launched, for example, in Serbia, where a new branch is going to be opened soon. PAWLICA Ltd. belongs to a group of companies with the highest level of credibility in the Czech Republic. The company has met the strictest criteria of credibility and reliability for the past ten years, and therefore belongs to the exclusive group of 0.2% of Czech companies that are allowed to use the highest AAA certification rating. Export deliveries to other Member States of the European Union are charged without VAT to persons registered for VAT in another Member State under the reverse charge regime. In case of export funding of deliveries, we discuss possible solutions on an individual basis, regarding the customers financial situation and particular business conditions. We have taken care of your crops for the past sixteen years. D Massing Prague CZ Opočno PL Wroclaw SK Piešťany Novi Sad SRB 12 13
OUR TRADEMARKS STELA STELA is a German family business, which has been making dryers for 120 years. They are world leaders in this business sector. The seat of the company is located in Massing near the Bavarian city of Passau. The company specializes in agriculture and industrial drying technology, which enables it to focus on technology development and increasing production effectiveness. They produce industrial belt dryers for sawdust, wood chips, sewage sludge, digestate, vegetables as well as trough dryers for non-free-flowing material such as pumpkin and other seeds. The agricultural dryers include tower dryers and mobile dryers for all kinds of grain. Stela is the only producer distinguishing between corn tower dryers and grain tower dryers, as it aims at constant reduction of drying cost. BROCK BROCK is an American silo manufacturer with an eighty-five-year-long tradition. BROCK is well-known for top quality, long-term values and state-of-the-art constructions. It is regarded a world leader in the field. The company was founded in 1957 with the aim of providing farmers with feed and grain storage bins. Its seat is located in Milford, Indiana. It is a member of the Chore-Time Brock (CTB) group, which supplies complete technology solutions from storage to poultry, hog and egg production. The group has an annual turnover of more than 1 bln USD and is traded on the American Stock Exchange. BIN BIN is a respectable Polish manufacturer of grain silos. The quality of its products and a strong position on the market is enforced by 24 years on the market and 50 thousand silos for 5 million tonnes of crops supplied. The company was founded in 1990, but the process started ten years before, when its founder Zygmund Krzeminski started to look for ways of storing grain on his farm. This is where he constructed first flat bottom silos made of galvanized steel. In 1997 he won an award for his contribution to Polish agriculture. The company s products include agricultural and export industrial silos with capacity of up to 2,200 tonnes. GEBR. RUBERG This German manufacturer of cleaners and pre-cleaners for cereals and other grain is proud to have been on the market since 1848. The company has developed a range of innovative solutions for grain cleaning. In 1975 they launched their first sieve cleaner with rotation system in the world, which they have been producing so far with the performance of up to 600 t/h. The seat of the company is located in Nieheim in Germany and its products are used not only in agriculture but also in chemical, food and pharmaceutical industries. SKANDIA ELEVATOR A specialized global manufacturer of high quality Swedish cereal and grain conveyors. They provide three product lines: Lite, Industry and Heavy Duty. The company is constantly looking for new innovative solutions for their technology and flexibly responds to the demands and needs of its customers. JE-MA The Danish family company JE-MA is located in Sahl in the middle of Denmark. Its product range, which has been developed gradually for 70 years, includes various types of conveyors and elevators, including special combined conveyors which allow a combination of horizontal and vertical transportation. The company also has a complete programme for loading and unloading of floor halls using belt conveyors. HUTCHINSON-MAYRATH The American company dating back to 1945 is currently the world leading supplier of grain handling equipment. It offers a complete range of auger, chain and belt conveyors, silo sweep unloading devices and a revolutionary technology of Grain Pump for easy loading and unloading of agricultural silos and halls. PFEUFFER Pfeuffer is a leading German manufacturer of laboratory equipment for measuring the grain quality. Its programme includes a complete range of equipment from moisture measurement in the field and at post-harvest lines to automatic and manual sampling of grain from trucks, cleaning, sorting and complete analysis of all samples. The Pfeuffer products are present in agricultural and food-processing companies worldwide. 14 15
PAWLICA TRADEMARK PAWLICA trademark = registered technology solution More than a hundred installations, approved technology and satisfied customers this is why we sell our solutions all across the Europe. PAWLICA trademark is protected by a patent. PAWLICA technology solution is a safe bet. It is guaranteed that PAWLICA post-harvest line will be constructed using proven European and American technologies and that their mutual integration and function has been tested on hundreds of installations. Combination of BROCK silos, STELA dryers, GEBR. RUBERG cleaners and SKANDIA conveyors received a PAWLICA post-harvest line protected certified patent. grain drying and storage technology 16 17
DRYERS Dryers Stationary Dryers 20 Mobile Dryers 28 Industrial Dryers 30 18 19
Stationary Corn Dryers STELA products are well-known for their high performance and a service life of up to 50 years. The quality of this technology is also confirmed by the number of installations in the Czech Republic, Slovak Republic and Poland, which has reached nearly 300 over the past sixteen years. Dryers MDB (Mais Durchlauf Breit) is intended for corn drying. These dryers operate with record low power consumption. Corn dryers are equipped with two fans for active heat recovery. Due to the pneumatically controlled interval discharge and differentiation of the shaft workspace they are able to dry wet corn of up to 35% of moisture in one cycle. Performance series and individual equipment of STELA dryers vary greatly, so it is up to the customers what performance and what equipment they choose. MDB dryers can also be used for other grain drying. Grain drying is an ideal preservation method, necessary for corn, sunflower seed and rape seed storage. It is scientifically proven that drying with STELA technology is grain-friendly, causing no harm or reduction of germinability. The dryer is made of hardened aluminium with an absolute resistance to corrosion. The final STELA solution is always tailor-made the customer is offered several options of heating, ventilation, heat recovery, dust and noise control, and automatic moisture regulation. All types of dryers are controlled by SIEMENS industrial automatic machine and a keyboard according to the data on the screen. Equipment: gas, oil or LPG burner, fluid heat exchanger direct or indirect heating external ladder secondary air flaps pockets for small rapeseed capture axial and radial fan fire protection system, fire extinguishing system, temperature monitoring insulation of hot, cold and central chamber dust control dust separator noise filter touch screen panel control and check remote access Advantages: unlimited capacity low consumption of the heating medium low energy consumption service life up to 50 years operation reliability active or passive recovery option flexible modular construction 20 21
BiTurbo even cheaper corn drying technology! NEW Nowadays it is possible to dry the corn even cheaper than before, thanks to a new BiTurbo drying technology, introduced by STELA last year. The new generation of dryers uses entirely new elements whose benefits are a significant reduction in heat consumption and less damage to the grain during drying process. The dryer uses two combustion burners, where each can be set to a different temperature. There is thus a twostage drying in which it is possible to significantly regulate the amount of heat and thus save a lot of money. The tower of a dryer is divided into two parts with different drying temperatures. Combustion burners are installed in a way to ensure optimal drying inside the drying channels. While very wet grain is dried at temperatures between 90 and 120 C in the upper part, final drying takes place in the lower part at much higher temperatures (130 150 C). As corn is dried gradually, there is no damage to the grain and a considerable amount of energy is saved. If the corn is not so wet, it is possible to use only one burner, the lower one, while the upper part can be warmed up only. Each of the two sections of the BiTurbo dryer has its own fan and uses different type of air. The upper part is heated by a mixture of fresh outdoor air and hot air from the lower drying section. This air mixture goes through the upper section with wet material and then it is discharged out of the drying tower, because it is not suitable for further recovery due to the high water content. At the lower section the fresh air is mixed with used air, again saving some energy. Another innovation ensuring efficient drying is the Combi-Air- Clean dust separation system. Both the BiTurbo and the Combi-Air-Clean technologies can boast very low emissions and significant gas and electricity consumption savings. Dryers Advantages: high capacity fuel and hot air consumption lower by 15 % two-phase drying no damage to the grain possibility to regulate temperature in the upper and lower section BiTurbo and Combi Air Clean technologies 22 23
Combi-Air-Clean BiTurbo The STELA Combi-Air-Clean- System increases efficiency of the grain dust, light impurity and petal separation in the entire dryer and, at the same time, reduces power consumption. Unlike at the conventional dust separation systems, the exhaust air at the Combi-Air-Clean system is split into two airflows. The very wet air stream (1) is exhausted from the upper part of the drying zone (2), where only a very small amount of dust is released and is sucked off together with the moist air by an axial fan (3) located at the roof of the dryer. The solid pollutant emission values of this exhaust air stream are significantly below the limit values due to a dust separation by a pneumatic flap. The airflow in the lower area (5) of the plant, however, contains more dust and a considerably lower amount of humidity. This airflow is exhausted by a lower radial fan (6) connected to the centro-separator (7) where the thorough separation of the dust takes place. The airflow released to the environment thus contains a very low level of solid pollutants. Compared to the conventional ways of dust separation the STELA Combi-Air-Clean System reduces the total dust emissions by up to 30 %. Thanks to a revolutionary air duct arrangement in STELA dryers with BiTurbo technology the required amount of warm air is reduced by up to 50 %, resulting also in a reduction of heat energy consumption by up to 15 % compared to conventional dryers with active heat recovery. The fresh air (1) is aspirated in the lower area of the drying plant, heated up by a gas burner for example (2) and led into the lower drying section, the so-called product area (4), together with preheated air from the so-called cooling zone (3). Contrary to the common drying process, here the grain is dried by a hot air of up to 150 C without damaging it as the humidity of the grain is about 18 20 % at this section. Still rather hot air (5) leaving the lower area is led into the upper zone of the drying plant by an axial fan (6), where it is mixed with fresh air sucked in at the upper part of the dryer. The fresh air is heated by another burner (7) to reach the temperature of 120 130 C. The heated air first goes through the upper wet grain section (8), before it is exhausted outside by the second axial fan (9). Dryers 24 25
Grain Tower Dryers GDB (Getreide Durchlauf Breit) series is designed for cereals and other grain drying, offered with capacity options ranging from 5 to 250 t/h. The final product is tailor-made with the required components. Operating parts are adapted to grain specifics and therefore they differ from corn dryers mainly in the distribution of ducts, the thickness of the product layer and the high performance of the fan, which is also required for efficient cooling during hot harvest season. GDB dryers can be also used for corn drying, but not at record low power consumption. Dryers Performance is one of important factor when choosing a dryer there are single-tower GDB models, and two-, three-, or four-tower GDB models for high performance options. For air heating one can choose a heater or exchanger, dust control or centro-separator can be an option for dust separation. Dryers can be equipped with passive or active heat recovery, partial or complete insulation, noise filters and some of the three systems for automatic control of the output moisture. STELA dryers are supplied with the SIE- MENS PC and keyboard- controlled according to the data displayed on the screen. Advantages: high reliability capacity 5 250 t/h low consumption of the heating medium long service life cereal, sunflower seed, soya and corn drying passive or active recovery Optional equipment: gas, oil or LPG burner, fluid heat exchanger direct or indirect heating external ladder secondary air flaps pockets for small rapeseed capture railings insulation of hot, cold and central chamber fire protection system, fire extinguishing system, temperature monitoring axial and radial fan dust control dust separator noise filter touch screen panel control and check remote access 26 27
Mobile Batch Dryers Mobile Continuous Flow Dryers The mobility of dryers has its advantages. The possibility to change place can be handy when working between more storage halls situated at different places, providing services to other subjects or when more businesses cooperate across different production areas. Another advantage is an immediate solution without delay caused by construction, since a construction permit is not required when one uses a mobile dryer. To obtain a mobile dryer you do not even have to have a post-harvest line. Such dryers can be used directly in the field or in the yard. They are loaded using a manipulator, a conveyor or a tank directly to the feeding hopper. Dryers may be unloaded directly to trucks by an integrated screw conveyor or straight to a hall. MUF series is particularly suitable for drying corn, sunflower and rapeseed. It is an ideal solution for farmers and businesses without a post-harvest line. MUF 45 series has a drying capacity of 45 60 t/day, MUF 70 offers a capacity of 70 96 t/day and MUF 110 series has a capacity 110 150 t/day, depending on the initial moisture of corn. The operating area of MUF dryers (Mais Umlauf fahrbar) consists of a vertical shaft between the outer and inner perforated wall. The drying air penetrates the layer of material across the area. The drying material is 0.5 metres wide and the wall perforation enables to dry even small rape seeds. Dryers The drying process is performed in batches. After the filling phase the process is run automatically for several hours. A record low consumption of heating medium can be compared to stationary tower dryers. Another advantage is a quick return on investment! Continuous drying process is preferred for small volumes of material. Mobile dryers are quick to install (after they were tested in the factory) and move about between different locations. UNIVERSAL series offers fully equipped dryers, mounted on the chassis, including a distributor. They have their own feeding hopper for loading and unloading from a height of 10 metres. They are designed for drying rape seed, cereals or corn continuously or in batches. The UNIVERSAL dryers are often supplied already assembled, using a crane, and installed straight inside the post-harvest line. The chassis carrying it is then returned to the factory. Advantages: Advantages: Equipment: quick installation construction permit not required the possibility to change location easy to use thanks to manual clocks and a screen acoustic and light notification when the drying process finishes automatic temperature regulation by MultiTerm tensometric moisture monitoring high quality drying without causing damage to the grain made of tempered aluminium service life more than 20 years the possibility of continuous dust separation of the conveyor during the whole process it separates only small particles while halves of grains remain inside integration into a post-harvest line change of location possible construction permit not required quick installation integrated loading and unloading conveyor gas, oil or LPG burner, fluid heat exchanger direct or indirect heating external ladder secondary air flaps pockets for small rapeseed capture axial air fan fire protection system, fire extinguishing system, temperature monitoring dust control dust separator noise filter touch screen panel control and check remote access 28 29
BTL Belt Dryers BT Belt Dryers BT dryers (Band Trockner) are fully equipped and suitable for outdoor installation in industrial plants producing wood pellets. They are available in capacity variations between 1 t/h and 50 t/h. BT Stela dryer is equipped with a special belt, the unique system of screw conveyors dividing the material on the belt into a cushion and a paddle wheel ensuring even drying of the entire material, MultiVent system to ensure optimal distribution of the drying air, sensors to control the constant moisture at the inlet and outlet, and additional safety features to ensure continuous operation with an annual minimum of 8,000 hours suitable for modern pelletizing lines. Thanks to forty years of specialization in drying and excellence in drying wet sawdust and wood chips Stela dryers are installed in pelletizing lines of companies such as CPM, Salmatec, Buhler and others. Dryers The new BTL dryer series (Band Trockner Lichte) represents a cheaper and easier solution for industrial belt dryers. It is ideal for using waste heat from biogas stations. The BTL dryer is suitable for drying various materials, such as digestate, sawdust, wood chips, sewage sludge, grain solubles, bentonite or agricultural products such as cereals, corn, alfalfa, beet chips, and the like. The principle of belt drying corresponds to the temperatures which can be obtained from cogeneration units or production, i.e. 60 120 C, and to the character of drying at low temperature with fast air flow. The drying process takes place in an enclosed drying tunnel on a plastic belt made of woven polyamide. This special belt can withstand temperatures up to 140 C. Thanks to the high density of its weav- ing very fine powdery materials can be dried. The belt serves as a natural filter and guarantees a low concentration of dust emissions. BTL belt dryers are constructed for the capacity of 8,000 hours/year and can even work in extreme weather conditions. Drying is controlled by the belt speed and capacity regulation of the fan. Dryers are equipped with high-quality monitoring system and they meet requirements for automatic mode of operation. Output moisture is monitored and it is thus possible to reach accurate values for subsequent granulation or any other form of treatment. Belt dryers are the only solution to achieve an even drying process with a guaranteed output moisture. Advantages: Advantages: state-of-the-art construction of belt dryers drying with waste heat water, vapour state-of-the-art construction of belt dryers drying with waste heat water, steam plastic belt capacity 1 20 t/h plastic belt capacity 1 50 t/h automatic drying and moisture regulation simpler design than BT series automatic drying and moisture regulation industrial components automatic cleaning constructed for capacity of 8,000 hours/year biogas stations, lower volumes of electricity production automatic cleaning constructed for capacity of 8,000 hours/year high volumes of electricity and biological fuels production 30 31
CLEANERS Pre-cleaners 34 Cleaners 36 CLEANERS 32 33
RUV Pre-cleaners CLEANERS 1 = good grain 2 = fine grain 1 3 = fine grain 2 4 = coarse grain Universal RUV pre-cleaners increase the effectiveness of not only the pre-cleaning process, but also the final cleaning of cereals, pulses and granular products. They are equipped with one sieve with change-over flaps. At the beginning of the process it is possible to use high performance pre-cleaning programme and then the sieves can be changed to carry out the final fine cleaning prior to shipping of the product. Their major advantage is considerable adaptability to a wide range of materials, high capacity and resistance. The system of automatically or manually operated distribution flaps of RUV pre-cleaners distributes the material into individual sieve sections (3 pieces at every level). Adequate ventilation system together with the regulation of quantity and pressure of air enable the pre-cleaner to cope with more humid materials containing significant amount of impurities. The aspiration Advantages: capacity 100 t/h 600 t/h 4 air ventilation versions emissions max. 10 mg/m 3 of air 4.5 metres long single-sieve model system at the inlet and outlet cascades ensures the required product purity. The manually adjustable distribution flaps allow you to sort the material into four fractions: quality 1, quality 2 (fragments without sand), overflow over the coarse grain sieve and the dust. The overflow and dust fractions are grouped together in the dust chamber. Using manual or pneumatic flaps they can be quickly grouped or divided. There are four air cleaning systems to choose from. The flow cleaning mode at the inlet and outlet and a recirculation cleaning mode at the inlet and outlet. The recirculation cleaning reduces the energy consumption and the amount of exhaust air. To reduce the dust level at the outlet a cyclone in combination with a sluice have been installed. For extreme dust reduction a fabric filter can be used to filter the exhaust air up to 2 mg/m 3. rotation movement of the sieves the possibility to change sieves and to adjust the outlet zones using flaps ideal for high capacity pre-cleaning and final cleaning at expedition Capacity data using 3 coarse grain sieves Type Capacity t/h Sieve surface m 2 Rye, wheat γ = 0,75 max.18 % Winter barley γ = 0,65 max.18 % Brewing barley γ = 0,65 max.18 % Rape γ = 0,60 max.14 % Peas, beans γ = 0,70 max.18 % Dry corn γ = 0,75 max.15 % Wet corn γ = 0,75 max.35 % γ = 0,40 max.16 % Rice γ = 0,55 max.18 % Total coarse grain sieve surface m 2 Total sieve surface m 2 RUV 100 105 90 90 85 85 100 50 75 30 4,5 4,5 RUV 200 200 175 175 160 170 200 100 150 60 9,0 9,0 RUV 400 400 340 340 320 320 400 200 300 180 18,0 18,0 RUV 600 600 520 520 480 500 600 300 600 360 36,0 36,0 Capacity data using 2 coarse grain sieves and 1 fine grain sieve Type Capacity t/h Sieve surface m 2 Rye, wheat γ = 0,75 max.18 % Winter barley γ = 0,65 max.18 % Brewing barley γ = 0,65 max.18 % Rape γ = 0,60 max.14 % Peas, beans γ = 0,70 max.18 % Dry corn γ = 0,75 max.15 % Wet corn γ = 0,75 max.35 % γ = 0,40 max.16 % Rice γ = 0,55 max.18 % Coarse grain sieve surface m 2 Fine grain sieve surface m 2 Total sieve surface m 2 RUV 100 70 60 60 45 50 70 35 50 20 3,0 1,5 4,5 RUV 200 140 120 120 110 115 140 70 100 40 6,0 3,0 9,0 RUV 400 280 240 240 220 230 280 140 200 120 12,0 6,0 18,0 RUV 600 400 350 350 320 330 400 200 400 240 24,0 12,0 36,0 Capacity data using 1 coarse grain sieve and 2 fine grain sieves Type Capacity t/h Sieve surface m 2 Rye, wheat γ = 0,75 max.18 % Winter barley γ = 0,65 max.18 % Brewing barley γ = 0,65 max.18 % Rape γ = 0,60 max.14 % Peas, beans γ = 0,70 max.18 % Dry corn γ = 0,75 max.15 % Wet corn γ = 0,75 max.35 % Sunflower Sunflower Sunflower γ = 0,40 max.16 % Rice γ = 0,55 max.18 % Coarse grain sieve surface m 2 Fine grain sieve surface m 2 Total sieve surface m 2 RUV 100 35 30 30 28 30 35 18 25 10 1,5 3,0 4,5 RUV 200 70 60 60 55 60 70 35 50 20 3,0 6,0 9,0 RUV 400 140 120 120 110 120 140 70 100 60 6,0 12,0 18,0 RUV 600 200 170 170 135 170 200 100 200 120 12,0 24,0 36,0 34 35
RV Cleaners RVS Cleaners The RV sieve cleaners are used for pre-cleaning and cleaning of cereals and grain, such as rape, corn, wheat and barley. They boast robust construction and reliable performance which makes them ideal for postharvest lines. The product to be cleaned comes from the field or from the accumulation silos. Light dust particles are removed by thorough air precleaning of input material, and even subsequently by air cleaning of outlet material. The operator is able to check and control the cleaning process easily though the inspection window. RV cleaners show little wear and tear and have few maintenance requirements. The sieves can be changed easily and quickly with a front entry and a split system. Thanks to all these properties they are popular with operators of post-harvest lines and storage halls. Type Wheat t/h 18 % 750 kg/m 3 Corn t/h 18 % 750 kg/m 3 Rape t/h 14 % 600 kg/m 3 RV40 40 30 25 RV60 60 50 30 RVS40 40 30 40 RVS60 60 50 50 RVS80 80 70 64 RVS100 100 80 85 RVS120 120 105 90 RVS150 150 135 120 RVS180 180 150 150 RVS240 250 210 180 RVS300 300 270 240 The RV models have a coarse grain sieve and a fine grain sieve, dividing the material into four main fractions quality 1, quality 2 (fragments), overflow over the coarse grain sieve and the dust. Overflow and dust are grouped together in the dust chamber. The cleaners have a system of automatic loading regulation and a cleaning air recirculation. While conventional cleaners with back-forward movement use only the middle part of the sieves for cleaning, Gebr. Ruberg cleaners use the whole surface of the sieves thanks to the circular motion. Under the sieves there are rubber balls ensuring their continuous cleaning. Circular motion and 100% utilization of the cleaning surfaces guarantee that each grain on the sieve will be tested and distributed accordingly. The RVS cleaners boast robust construction and reliable performance, which makes them ideal for postharvest lines receiving the product from the field or from the accumulation silos. They provide air precleaning of input material as well as subsequent air cleaning of the output material. They are simple to set up and checked through the inspection window enabling the operator to have the best control over the ongoing cleaning. The RVS cleaners are equipped with an automatic loading regulation, based on sensors of lower and upper levels indicating loading, which always assessing the flap position. This solution ensures a machine is used up to its maximum capacity. The cleaners contain air recirculation system inside the air pre-cleaning unit. To reduce the dust level they can be fitted with fabric sleeve filters and achieve a maximum dust level of 10 mg/m 3 only, also thanks to low air flow at the outlet. The RVS cleaners offer a unique construction of the sieve unit with a stable tilt of 3 and a circular movement. While conventional cleaners with reciprocation movement use only the middle part of the sieves for cleaning, Gebr. Ruberg cleaners use the whole surface of the sieves due to its circular motion. Under the sieves there are rubber balls, which ensure their continuous cleaning. The circular motion and 100 % utilization of the cleaning surfaces ensure that each grain on the sieve will be tested and distributed accordingly. The sieves are located in different levels, which make the cleaners achieve capacity of up to 300 t/h at reasonable layout dimensions. The cleaners are equipped with coarse grain sieves, fine grain sieves and sand sieves, separating even sand particles very effectively. They are therefore suitable for businesses producing fodder mixes. Gebr. Ruberg cleaners are intended for pre-cleaning and cleaning of cereals and grain. The material is divided into four main fractions quality 1, quality 2 (fragments without sand), overflow over the coarse grain sieve and the dust. The last two fractions, overflow and dust, are grouped together in the dust chamber. These fractions can be grouped or divided very quickly due to the manual or pneumatic flaps. CLEANERS Advantages: Advantages: Capacity 40 t/h 60 t/h capacity 60 t/h 300 t/h quick sieve replacement cleaning air recirculation low wear, tear and maintenance requirements automatic loading regulation thorough cleaning and pre-cleaning of cereals and grain world leader in malting barley maximum dust level 10 mg/m 3 circular movement of sieves long service life low maintenance requirements 36 37
BIN SILOS BIN SILOS 38 39
Farm and Industrial Silos BIN SILOS Polish BIN silos produced mainly for export are a great solution for storing crops at small to middle size silos. They are cylindrical tanks made of smooth steel galvanized (275 g/m2) sheets made in Finland. Individual pieces are attached by high-resistance bolts and joints are sealed to prevent water from getting inside the tank. The thickness of the side wall sheets of NBIN 501 models and above is the same (2 mm) along the total height of the silos. Internal vertical supports are installed to ensure the product safety. The roof is constructed to carry a footbridge together with loading equipment and other items necessary for easy access to maintenance and check of the silos. The BIN silos are manufactured in capacities 10 2,200 tons. The construction of BIN silos allows for a maximum height of the cylindrical part of the silo to be 11.45 meters. This construction limit is compensated by a basic BIN silo equipment including a full-grid perforated floor (perforation in terms of rape seed storage is platitude), which is installed on pre-cast concrete blocks. For a simple and easy operation there is a comfortable and solid spiral staircase, a ladder with a safety cage, internal ladder, roof stairs with railings and, last but not least, sufficiently large check and inspection manholes situated at the lower part of the silo as well as on the roof. All steel structures are tailormade directly at the factory, according to the current EU standards. They fit perfectly and what is more, they comply with the strictest occupational safety and health regulations. Aeration is vital for high-quality long-term storage of any biological material. In terms of the BIN silos the air intake is provided by powerful carefully designed radial fans made in the Czech Republic. The roof vents make Advantages: capacity 10 1,500 tons 50 years of service life perforated floor sure that the exhaust air leaves the silo and they serve as a passive aeration system under the roof of the silo. In case of condensation under the roof of the silo, e. g. rapid changes of the outdoor temperature, an anticondensation exhaust fan is installed on the roof to ensure active ventilation of the space under the roof. Due to its easy construction the 500-ton BIN silo can be built in a few days! screw and sweep auger conveyors stairs, footbridges, ladders, inspection manholes galvanization (275 g/m 2 ) Silo model NBIN 10 NBIN 20R NBIN 20WR NBIN 60R NBIN 60WR NBIN 100RU NBIN 100WRU Capacity (m 3 ) 15,6 30,7 38,2 76,9 91,7 134 177 281 347 695 1264 1560 1713 2019 2461 2902 Storage capacity (t) 13 24 30 60 72 105 139 220 271 543 986 1217 1337 1575 1920 2264 Diameter (m) 2,29 3,18 3,18 4,46 4,46 5,35 5,35 6,68 6,68 8,59 11,46 14,32 14,32 14,32 17,19 17,19 Total height (m) 4,58 4,76 5,72 6,08 7,03 7,13 9,04 9,56 11,46 13,87 14,72 12,7 13,65 15,5 14,8 16,7 NBIN 200U NBIN 200WU NBIN 500 NBIN 1000 NBIN 1500N NBIN 1500P NBIN 1500 NBIN 2200P NBIN 2200 40 41
BROCK SILOS Flat Bottom Galvanized Silos 46 Hopper Bottom Silos 48 BROCK SILOS 42 43
Footbridges Wide solid footbridges ensure easy and safe access to conveying technology and inspection manholes. Stairs Optional roof and spiral staircase for comfortable access to inspection manholes and footbridges. Fitted with railings and rest areas. Roof construction Innovated roof construction allows extreme load at the top of the silo. BROCK SILOS Roof vents They ensure optimal air flow and are equipped with wire grate to prevent birds from getting into the silos. Inspection manholes 1.7 m high door at the lower part of the silo and inspection manhole on the roof allow easy access inside the silo. Discharge screw conveyor Reliable long-standing construction for mechanized material removal. Ventilated floor It ensures perfect conditions for ventilation. Perforated floor specifically for rapeseed also available. TRI-CORR grid system and PARTHENON supports ensure extraordinary solid floor. 44 45
Flat Bottom Galvanized Silos BROCK S EVEREST GRAIN BIN LINE IS DIFFERENT & BETTER EVEREST BIN LINE INNOVATION new peak support connec on new model sizes, greater heights and larger TRI-CORR patented panel profile with a reinforcing rib in combination with the PARTHENON supports ensure a very high strength and resistance even at the highest measurable pressure generated by grain column. The air intake is ensured by high-pressure radial fans made in the Czech Republic. In order to prevent condensation under the roof of the silo we install anti-condensation exhaust fans. The unloading process begins with the side discharge draw system followed by a sweep unloading system ensuring complete and thorough unloading. the silo. The silos are also equipped with a weather station to switch on ventilation automatically depending on the outside temperature, humidity and time. All the BROCK silos imported into the European market are designed according to the requirements and demands specified by the so-called Eurocodes 3 and they can be insured against risks. capaci es enhanced roof peak load strength up to 130.000 pounds (59.000 kg) excep onal sidewall strength exclusive bin anchor system easy acces to bin interior maximum storage capaci es of up to 43.000 m³ The BROCK silos are equipped with a local control SIE- MENS software providing the operator with an overview of essential information. It informs of the progress of loading, filling up and temperature inside the silo. There are suspension thermometric cables measuring temperature, its sensors being placed every 1 1.5 metres, in order to register information over the entire height of Corrugations on side supports and sides of triangle-shaped center support leg contribute added stability and increased strength. The clear-punched aeration holes and flat crown of Brock s Tri-Cor Floor aid bin sweeps and ease grain clean-up chores. Perforation for rape and other small sized grain. BROCK SILOS Storing the crops after harvest in high-quality storage positively influences its subsequent value. For this reason we supply our post-harvest lines with American galvanized BROCK silos made of corrugated metal sheets. They are available in a very wide range of sizes and capacities. Based on the increasing global demand for storage of a growing number of commodities a new silo model called EVEREST has been developed. Thanks to its innovative design the BROCK silos can be as high as 40 rings and have a diameter of 47.6 meters. These are the largest dimensions available on the market, proving the uniqueness of this technology. The construction of the cylindrical part of the silo and roof has undergone a complete reconstruction. It can now carry an extreme load of 59,000 kg at the top of the silo. Just for your information, the largest BROCK silo was built in the US, near Chicago, Illinois. It has a diameter of 47.6 metres and 33,000 tons of grain can be stored in it. To be able to ensure high quality of the stored material adequate aeration is a must. The silos are aerated by a full-grid floor or aeration ducts, which are laid in the baseplate of the silo and their shape is designed strictly according to requirements for aeration. The enormous height of the silos also generates extreme pressure on the grid panels and their supports. The BROCK EVEREST flat bottom silos Diameter (m) 4,6 5,5 6,4 7,3 8,2 Rings 7 22 7 26 7 30 7 35 7 39 Capacity (m 3 ) 99 296 145 505 199 793 264 1208 338 1705 Total height (m) 7,16 22,62 7,99 22,62 7,44 26,12 7,71 30,45 7,96 33,99 Diameter (m) 9,1 10,1 11,0 12,8 14,6 Rings 7 40 7 40 7 40 8 40 8 40 Capacity (m 3 ) 423 2163 518 2624 624 3130 973 4282 1298 5620 Total height (m) 8,23 35,05 8,50 35,33 8,75 35,57 10,12 36,12 10,30 36,63 Advantages: capacity 100 33,500 tons numerous options in terms of dimensions quick construction screws with integrated pads high quality ventilation ducts or full-grid floor with small-hole perforation ideal for small grain storage, such as rapeseed service life of up to 50 years side wall stiffeners both outside and inside galvanized 275 g/m 2 in standard models, 450 g/m 2 optional high resistance to acid rain diameter 4.5 47.6 m Diameter (m) 16,5 18,3 22,0 22,9 23,8 Rings 8 40 8 40 8 40 9 40 10 40 Capacity (m 3 ) 1677 7148 2113 8867 3163 12891 3795 14021 4497 15201 Total height (m) 10,82 36,82 11,25 37,25 12,28 38,31 13,23 38,44 14,30 38,68 Diameter (m) 27,4 32,0 40,2 47,6 Rings 13 40 12 40 18 36 18 25 Capacity (m 3 ) 7601 20428 1002 28127 22873 41263 33083 43073 effective unloading optional side discharge draw height of the cylindrical part up to 32.5 m Total height (m) 17,08 39,75 18,29 41,06 25,58 40,21 27,69 33,38 46 47
Hopper Bottom Silos The construction of the BROCK hopper bottom silos is also based on the construction principles of the EVER- EST model. As such they comply with the Eurocode specifications and do not require additional calculation for the European market. These containers are designed for short term storage, for example prior to the drying process. They may also serve as manipulation containers in various processes. The hopper bottom can be fitted with aeration system also suitable for rape and other small seed storage. Hopper bottom silos can be also equipped with a side discharge draw unloading system. The BROCK EVEREST hopper bottom silos Diameter (m) 4,6 m/60 5,5 m/60 6,4 m/60 4,6 m/45 Capacity (m 3 ) 105 250 158 443 227 640 97 268 Total height (m) 10,36 19,30 11,43 23,62 12,47 25,47 8,95 19,52 Diameter (m) 5,5 m/45 6,4 m/45 7,3 m/45 8,2 m/40 Capacity (m 3 ) 146 449 205 618 277 817 354 1037 Total height (m) 9,68 22,69 10,41 23,42 11,14 24,14 11,24 24,24 Diameter (m) 9,1 m/40 9,1 m/50 11,0 m/40 11 m/50 Capacity (m 3 ) 450 1346 485 1329 682 1897 737 1952 Total height (m) 11,89 25,71 13,61 26,62 13,13 26,13 14,90 27,90 BROCK SILOS Advantages: hopper bottoms of 45, 50 and 60 aeration for rape seed and cereals diameter 4.6 10.97 m capacity 80 1,545 tons Optional equipment: roof landing with a railing at the top of the silo roof staircase internal ladder external ladder with a safety cage 48 49
50 51 BROCK SILOS
CONVEYORS Skandia 54 JE-MA 55 Ruberg 56 Hutchinson 57 CONVEYORS 52 53
Skandia JE-MA For higher capacity of grain transportation starting at 60 t/h within a post-harvest line we use conveyors made by SKANDIA, a leading European manufacturer from Sweden. Their product range includes various types of bulk conveyors for horizontal transport and elevators for vertical transportation. The conveyors are fully galvanized and manufactured in compliance with the EU regulations. Under the bulk conveyors and elevators SKANDIA offers three series. L Conveyors (Lite) are designed for smaller warehouses and lines with transport requirement of up to 60 t/h and are used primarily during the harvest period. These bulk conveyors and elevators are intended for farms with a turnover of up to 3,000 tons per year. The I series of conveyors (Industry) is suitable for businesses with year-round operation of up to 50,000 tons per year and performance demand of 40 120 t/h. Bulk conveyors have a classic design, where the grain travels in rectangular chambers being carried by plastic carriers (HDPE) fastened to a robust high-resistance chain. Both L and I series include loading, unloading and curved bulk conveyors of 15, 30 and 45 angle, and inclined conveyors with high carriers, which work up to an angle of 45. The H series (Heavy-Duty) is designed for continuous year-round operation, e. g. in ports and rail terminals transporting more than 30,000 tons per year. Bulk conveyors and elevators in this series are available in capacity of 60 600 t/h. The construction of conveyors in these series is very robust and has a long service life. This is thanks to 8 mm thick plastic padding at interfaces of elevator and bulk conveyor floors. Curved conveyors for the most challenging series with performance of up to 200 t/h have been recently introduced. All SKANDIA conveyors use a reliable and powerful NORD drives. On request, we can supply Ex conveyors for explosive environments. Another additional equipment is residue-free design of bulk conveyors, outlet slides which can be opened either perpendicularly to the axis of the conveyor, or with moving along the axis of the conveyor, which significantly saves space on the operation footbridge above the silo. Bulk conveyors are equipped with end switches to prevent engine overload and blocking of the conveyor. Elevators can be fitted with belt alignment sensors. Speed monitor, drum back stop with guard and the bucket belt resistant to rape seed oil is already a part of standard equipment. Newly SKANDIA produces a discharge sweep system with a chain and plastic carriers. This new product should ensure more thorough and grain-friendly discharge of the product from the silo. The SKANDIA products are suitable for various purposes within a post-harvest line or storage system. The JE-MA conveyors are a solution for material transport capacity of up to 60 t/h. Their advantage is high capacity at low energy consumption and very good design solutions. The principal company products are conveyors for grain, cereals, various seeds, granulates and fertilizers. The conveyors are fully galvanized and manufactured in compliance with the EU regulations. They include standard bucket elevators, screw conveyors, belt conveyors, and combined chain conveyors. JE-MA is a Danish manufacturer producing also intake hoppers and drive-over intake pits with a built-in steel trough, which is an integral part of the intake conveyor. In case of low groundwater levels we are able to make a lower double intake pit. A very successful product of the JE-MA company is a chain conveyor with the possibility to change direction by 90 or 45 turn. The conveyor is made of a strong chain with rubber carriers that carry the grain in filled chambers. The change of direction is enabled by a special turn station which moves both the pulling and reversing part of the turn. T20 model s capacity is 20 t/h, T40 model s is 40 t/h. T20 and T40 combined chain conveyors are made of standardized components of the modular system made of galvanized smooth sheets. The material is transported by a strong roller chain with riveted rubber carriers. The horizontal section may be adjusted to serve as an intake hopper. What makes these conveyors so special is the possibility of simultaneous horizontal and vertical transport of material under a single drive. Additionally, the entire transport of material takes place above ground so there is no need to dig the heel of the elevator into the ground. The drive options are a gear motor or gear with pulleys and V-belts. The JE-MA T20 / 40 system combines an intake hopper with a discharge conveyor. The hopper can be standing on the ground or can be placed inside a pit (drive-over grids). The intake capacity is up to 40 t/h. The T19V belt conveyors represent a modular system based on standard elements which, when properly combined, can be assembled into various transport systems. The advantages are small dimensions, low weight, varied assembly options and easy construction. T19V conveyors are suitable for horizontal or slightly rising transportation. Their performance ranges from 25 to 50 t/h. For higher performance the following models are available: T50, T51, T52 and BC400 with a capacity of 60, 105, 150 and 300 t/h respectively. The belts are oil-proof, chambers are made of galvanized coated sheets with plastic rollers. For larger inclination angles conveyors can be equipped with a belt with corrugation or a rake. A standard JE-MA production program also includes bulk conveyor (T49, T57 and C300) and bucket elevators (T53, T54, T55 and E300) with capacity 60 225 t/h. CONVEYORS 54 55
Ruberg Hutchinson Whenever there are special requirements, be it for capacity, construction or operation, services of German manufacturer GEBR. RUBERG are a solution. In cooperation with this manufacturer, we are able to incorporate special conveyors into our lines, ranging from models powder-like materials to ones with coarser zinc layer. Elevators can be supplied with shafts with circular cross section for increased structural strength of the elevator. Capacity ranges between 25 and 300 t/h. The robust and outstanding construction of GEBR. RUBERG conveyors is suitable for the most demanding operation. Nowadays, we often include a new element in our projects: an innovative and unconventional technology for material transportation in silos, so called GRAIN PUMP by Hutchinson, a US manufacturer. This very simple and yet highly effective system has many advantages, such as gentle transport, high capacity and lower engine power requirements compared to traditional bulk conveyors or elevators. The indisputable advantage is also lower wear and tear compared to traditional conveyors. The grain pump is made of galvanized tubes, where inside there are circular plastic (polyurethane) carriers attached to a robust steel chain. The system is designed to be gentler to the grain. It is more grainfriendly than a traditional way of transport in which damage to the grain may occur when the grain falls from one conveyor to another. This has been proven by a research conducted at the Mendel University in Brno. When testing transportation of wheat, malting barley, rape seed and corn no damage to the grain has been found. For this technology PAWLICA Ltd. won the Grand Prix award at the Techagro exhibition. The grain pump technology is designed to be flexible and easy to install. The conveyor is always installed above the ground so there is no need for costly and complicated construction work. Although it is an American technology it is installed with Czech engines and electrical components in the Czech Republic. Another advantage is its compliance with the EU standards. CONVEYORS Advantages: capacity 25 300 t/h long service life low maintenance costs easy installation Advantages: capacity: 55 t/h, 108 t/h, 162 t/h, 270 t/h a 486 t/h easy installation and maintenance automatic chain tightening horizontal and vertical transport with one or two engines grain-friendly transport lower investment requirements outlet slide with servoengine or manual control drive corner with Dodge gear industrial double chain model and stronger piping 56 57
HOPPERS HOPPERS 58 59
Hopper Tanks Czech hopper tanks are used for transport or for balancing different capacity within post-harvest lines. The tanks of a rectangular shape and a hopper are made of steel. Due to the design variability we can offer the optimal size that best meets the specific requirements for a particular project. Rectangular steel tanks can have a capacity of up to 100 tons. They can therefore be used for storage at smaller dryers. The expedition tanks have capacity 30 60 tons and are located 4.2 meters above the ground. The discharge hoppers are available with manual, electric, pneumatic or combined outlet slides. Both expedition and storage tanks can be fitted with tensometric weighing system. As a result, a 30-ton tank can be weighed with an accuracy of ten of kilograms. The tanks generally have a painted surface finish. Tanks intended for outdoor use are covered with trapeze plates (AlZn). Hopper tanks are available in different colours on request. HOPPERS 60 61
AUTOMATIC CONTROL AUTOM. CONTROL 62 63
Automatic Control Post-harvest lines supplied by our company are usually controlled by two systems by a push button system with a technology chart on the switchboard door or by a computer. Regardless of the control system, on each drive we install a so called deactivation board so that, in case of failure, any drive can be deactivated, switched off, or switched back on to automatic mode. Potential failure statuses are monitored and signalled by light or sound. A push button system with a technology chart on the switchboard door This is the easiest system of semi-automatic control system. The operator uses buttons on the switchboard to select a pre-set programme. The system is equipped with a system blocking unwanted statuses and with failure signalization. Temperatures inside the silo are read manually using a silo control module which is connected to the thermometer cables. Computer control It is the most modern control system, where the operator launches a selected programme by clicking the mouse on the control chart on the PC monitor in the control room. The system is programmed to meet the needs of the investor. All the necessary data are monitored and recorded. The current status of silo filling, the grain temperature inside a silo, outdoor temperature and humidity are the basic elements that the operator can see and evaluate directly on a PC monitor. The system of activating ventilation is dependent upon the current outside air temperature, humidity and time, and its goal is to balance the temperature difference inside and outside the silo, to prevent condensation and consequent damage of the stored grain. Important data can be displayed using a remote access, e. g. on a mobile device. The remote access can be also used to act when immediate maintenance is needed or to monitor system failures identifying possible defects. AUTOM. CONTROL 64 65
DUST SEPARATION DUST SEPARATION 66 67
Dust Separation Unlike before, nowadays there are increasingly stricter solid pollutant emission limits which increases the demand for dust-free technology and equipment used in our post-harvest lines. In collaboration with manufacturers, we propose appropriate solutions to individual project requirements. Reducing dust emissions is required at almost all part of a line intake pits, cleaners, dryers and transportation. Intake pits aspiration GEBR. RUBERG Filter wall with textile filters and vibration no material loss in process As the material is loaded, a dust is sucked in the filter wall, where the dust particles remain on the textile hose filters. The clean air is then exhausted into the atmosphere. When the loading process is finished and the dust cloud disappears, the sucking fan is switched off and the vibration of filter hoses is switched on. The captured material then falls back to the intake trough. Extraction wall with a decentralized filter This method of extraction of intake pit is designed in a similar way as the filter wall. The difference is that the air is filtered outside the extraction wall. Technological air is extracted along the entire length of the pit. The stream is then led into an industrial filter with pneumatic vibration and rotating pressure sluice on the outlet of the filter. The rotating sluice gradually releases the captured particles for further processing. Aspiration of grain cleaners GEBR. RUBERG The GEBR. RUBERG cleaners have recirculation chamber and use cyclones and small-size filters, unlike other separators. The flow rate at the cleaner outlet is in fact equal to approximately only 10 % of the total amount of air, with which the cleaner works, thanks to the recirculation of air inside the machine. Cyclonic separator Gravity-aided cyclonic separators are basic and in most cases a satisfactory solution for the separation of solid pollutants from the air released into the atmosphere. The separators usually have a spiral inlet. Technological air inside the cyclone changes direction sharply several times, which causes gravitational separation of solid pollutants. The output concentration of solid pollutants depends on the dimensions, size and particular working conditions, but should not exceed 150 mg/m 3 of the exhaust air. Industrial filter The shape is very similar to the cyclone, but inside it there is a system of textile filter hoses. Incoming technological air passes through the filter layer which captures the separated particles. The filter is equipped with an automatic system of back flushing, which vibrates the hoses and releases the particles into the filter hopper. There is a rotating pressure sluice at the hopper outlet. The output concentration is maximum 10 mg/m 3 of the exhaust air. Dust separation of grain dryers STELA STELA dryers can be equipped with two kinds of dust separation system. Dust separation flaps The flaps are pneumatically controlled, situated at the fan outlet. They close when the material is being discharged from the dryer. This way there is no dust stir inside the dryer when the negative pressure drops. Centro-separator The device operates on the principle of a multi-level flow centrifugation. The centrifugal force moves the dust particles towards the walls of the separator, where they reduce their speed and are separated from the air flow. Then they are directed to the discharge nozzle, which works on the principle of a cyclone separator and where a final separation takes place the air flow changes direction again by 90, separating the remaining particles. The final dust concentration in this type of separation is 20 mg/m 3. The Combi- Air-Clean technology uses a combination of both ways of dust-separation. Aspiration of transportation equipment SKANDIA, JE-MA, HUTCHINSON and RUBERG transportation equipment is secured against dust leakage and water intrusion, but they can be additionally equipped with a dust separation system. This can be done by a decentralized aspiration of all transportation equipment through holes and special extensions integrated into the conveyor or elevator. Another way to do this is using SKANDIA aspiration device. DUST SEPARATION 68 69
LABORATORY EQUIPMENT Truck Samplers 72 Moisture Meters 73 Analysers, Sorting Machines and Cleaners 75 Quality Measuring Machines 76 LABORATOry 70 71
Truck Samplers Moisture Meters Commercial Moisture Meters Automatic track sampler Rakoraf and Rakoraf 2 Linear The RAKORAF CEE Core Sampler is the fastest and easiest method to take an accurate sample from an open trailer. The sample is taken while the trailer is still on the weighbridge. The telescopic arm with the core tube can be extended or retracted, be turned horizontally 0 to 350 degrees, and can also be raised or lowered vertically. When the core tube is forced downward into the load, the grain, due to the down pressure, is pushed upwards into the inner chamber of the core tube and carried to the receiving chamber located in the weighbridge office via steel and plastic tubing. Sample Spear Pfeuffer Mechanical samplers are used for obtaining average samples. They allow the sampling up to a depth of 2 m. Mechanical sample spear Pfeuffer can be used in Rakoraf advantages: Correct sampling no vacuum cleaner effect For any flowable product Well tried and tested Fair to both buyer and seller Leading in Europe Patented ModelSample Spear Pfeuffer The compact handheld remote control which has all moving functions in one handle can activate up to 3 moving functions at the same time. The remote control speeds up the operation and it is possible to take 5 samples in 40 seconds. The joystick is connected to the sampler with a single multiplug and if required you can replace your old type push button unit very simply. Push button for working lamp and horn. The sampling procedure with a RAKORAF 2 LINEAR Core Sampler is the fastest and easiest method to take an accurate sample from an incoming batch. all possible storage places of cereals and pellets, like granaries, storage halls, trucks, railway waggons and similar. Rakoraf 2 Linear advantages: Sampling range of up to 18.8 m x 8.8 m Construction on columns or wall bracket Proven and patented Rakoraf sampling technique Easy-to-use remote control Fast installation Suitable for all kinds of grains like cereals, oil seeds and starch crops GRANOMAT GRANOMAT is fully automatic moisture meter made for seed production, grain trade and stores, warehouses, salting and feed plants. The GRANOMAT measures the capacity (dielectric constant) of the whole grain sample. It determines the moisture of the product as well as the bulk density (specific weight) of the whole corn. Grinding of the sample is not necessary. The GRANOMAT can test all cereals, legumes, oil seeds, maize and malt. The memory stores up to 100 different calibrations. The sample volume is 600 ml. The measurement is fully automatic. The user puts the sample into the funnel of the GRANOMAT, chooses the requested product and presses the key MEASURE. The input of a sample identification is also possible. The GRANOMAT fills the measurement cell automatically. This guarantees a constant bulk density. The stripping device removes the grains which are not necessary for the measurement and provides for a constant volume. The measurement of the capacity, weight and temperature of the sample is carried out within a couple of seconds. The GRANOMAT indicates the measured product moisture, the bulk density (expressed in kg/hl) and the temperature of the sample and prints the results by means of the integrated printer. No Grinding Fully Automatic Integrated Printer High Precision* Easy Handling Big Sample Volume HE 60 & HE 90 Moisture meters HE 60 and HE 90 are suitable for the moisture measurement of almost all types of cereals. Both instruments can also be used especially for flours and coarse meals. A total number of more than 200 product calibrations is available. Grind a sample of 20 ml by means of the hand mill. The samples falls directly into the measurement cell without being heated. Screw in the top section of the measurement cell as far as the stop. The homogeneous press cake guarantees a consistantly high accuracy. Select the product by pressing the corresponding key. After 30 seconds the exact measurement result appears on the display. Correction of the temperature are made automatically by the HE s themselves. Measurement method Automatic temperature correction Official approval Ease of servicing More than 200 product calibrations is available LABORATOry 72 73
Moisture Meters Analysers, Sorting Machines and Cleaners Portable Moisture Meters HE 50 SPECIAL & HE 50 STANDARD The HE 50 completes the measurement in seconds, automatically corrects the temperature and displays the measurement result. No adjustment is required since the HE 50 offers very high accuracy. Four of the fourteen product programs can be selected from over 200 available products for your HE 50, e.g. cargo, peanuts, milo corn, green coffee etc. This allows a universal application of the HE 50 for grain, grass, vegetable and flower seeds, etc. Floury products can be measured by means of the special cell for floury products, available as option. The measurement cell which has been specially developed for agricultural use allows the most diverse products to be measured. The homogenisation of the sample in the new measurement cell creates the best conditions for precise moisture measurements. This means that the HE 50 offers great reliability for freshly harvested grain and other crops within a wide measurement range. The HE 50 is suitable for the temperature measurement as well. In connection with a temperature rod (1 m or 1.5 m) you can measure the temperature in stored goods and piles of grain. The temperature in bales of straw and forage can be measured by means of the new temperature rod for straw and forage. As a result of its highly modern technology, the HE 50 is easy to service and offers a long service life. Very easy handling Fast measurement High precision Automatic temperature correction High measurement range to over 30 % moisture 14 calibrations included HE LITE The HE LITE has been especially designed for controling the moisture on the field during the threshing process and for checking the moisture absorption inside the combine-harvester. The HE LITE is used for the regular moisture measurement during the drying process and during the storage to avoid losses in quality. The HE LITE is suitable for the moisture determination of cereals, oilseeds and humid maize. The integrated measurement cell of the HE LITE is based upon the Pfeuffer-principle proven for more than 40 years. High measuring range Easy menu operation Proven principle of measurement Possible adjustment of calibrations Averaging Favourable price GRANOLYSER NEW The GRANOLYS- ER is a diode array based NIR analyser which is suitable for a wide variety of different grains and seeds, like cereals, oil seeds, legumes or corn. It has a wavelength range from 950 to 1550 nm with a high resolution and therefore provides the best basis for precise and expressive results of parameters like moisture, protein, oil, sedi, gluten. Fill in the sample, select grain type on the integrated touch screen display and push the start button. The GRANOLYSER starts the transport of the 600 ml sample and measures 1.500 scans. The result of the integrated calibration models is displayed. The user can also print the results. GRANOLYSER has an export file function so that generated files can easily be opened on your office computer (with software like MS Excel). Quick results in less than 40 seconds Big sample volume: 600 ml High res. NIR diode array technology More than 1000 single scans per sample Coloured 8 LCD touch screen display Integrated printer Attractive price SORTIMAT SORTIMAT is efficient and rapid laboratory screening machine for the grain trade, stores, maltsters, breweries, laboratories and mills. The SORTIMAT is suitable for carrying out the sorting (according to EBC-method, MEBAK 2.3.1) and for determination of the boldness of brewing barley. It supports the Besatz determination (according to ICC standard 102/1 and 103/1) of wheat, barley and rye. Further possible applications are the control of pre-cleaning machines and vacuum dust extraction plants. Determination of the boldness of brewing barley Quality assessment of cereals available with 3, 4 or 5 sieves Solid construction Long service life Maintenance free MLN/SLN Sample Cleaner The sample cleaner is very versatile and can be used on a wide range of products ranging from oil seed rape to maize and beans. We offer model MLN with straw and sand sieve and model SLN3 with additional sorting sieve. Selection by sample gives an accurate assessment of the total consignment. Selection based on sample makes it possible to accept quality grain or alternatively reject that which does not meet the specified standards at intake. The identification of quality and type of impurities in a consignment and the actual grain size is important when selecting suitable grain for seed, malting barley, intervention etc. A similar standard of cleaning as that on cereals can be achieved on peas, beans and more difficult products such as sunflower seeds etc. A large feed hopper can be supplied to enable the cleaner to be used for the separation of pedigree seed from experimental yields. MLN model is equipped with deawner, aspiration and sieves for straw and sand. SLN model checks impurities and grade. SLN3 has one additional grading sieve with ball cleaning system. SLN4 has two additional grading sieves with ball cleaning system. Practical use during harvest season Fully automatic cleaning no maintenance. The screens are self cleaning being equipped with the well proven ball cleaning systern. New locking system for sieves secure quick change of sieves. Vibration free operation. LABORATOry 74 75
Quality Measuring Machines TANNOMETER Analysis of phenolic substances in beer The TANNOMETER is suitable for testing most clear liquids and those which contain phenols such as beer, wort, extract of brewing barley, malt and hops, grape and apple wine, fruit juices and vegetable extracts. The comprehensive analysis allows statements regarding good and poor characteristics like sediment formation, colour intensification and taste changes for routine controls. The operation is menue controlled. The TANNOMETER combines a dosing device, temperature control, magnetic stirrer, turbidimeter, photometer and evaluation computer with plotter. The measurement chamber has a focused light of constant intensity directed through it. The thermostatically controlled sample absorbs and scatters this light. Whilst the first sensor measures this light at a wavelength of 510 nm the second sensor measures scattered light at an angle of 90 The automatic modes support the analysis of: Tannoid content Protein sensitivity Reducing capacity Chill haze Ammoniumsulfate titration limit FRIABILIMETER Malt analysis The FRIABILIMETER allows an easy and fast determination of the brewing value of malt in the practice, immediately after kilning. Irregularities during the malting process can be detected and corrected. The brewery can determine the malt quality immediately upon delivery and apply consistent malt blends accordingly. This avoids unnecessary problems. A malt sample of 50 g ±0,01g is weighed and filled into the FRIABILIMETER. Then the instrument is switched on, the lateral pull handle is pulled downwards and locked into the bottom stop notch. After 8 minutes the instrument switches off. The glassy malt parts, which remained inside the sieve drum are weighed and the friability value referred to 100 % is calculated. Fast and easy analysing method Practice-oriented determination of the brewing value Simplifies the malt analysis Robust and solid construction CONTADOR Seed counter CONTADOR counts and fills all seeds from 0,3 mm up to 15 mm. The feed container is held in place by an electromagnet and vibration induced during counting. The material to be counted reaches the outlet and falls into the receptacle through a photoelectronic counter. High counting speed Precise count Easy to use Quiet operation Flexible CONTAFILL Filling station The semi-automatic filling station CONTAFILL is an additional equipment for the seed counter CONTADOR. It offers continuous fill by immediate removal of filled bags or automatic stop when all the bags on the carousel are full. It fills all kinds of paper or plastic bags, plastic or glass bottles, it has choice of required quantity and checks for missing bags or bottles. Fills all kinds of paper or plastic bags, plastic or glass bottles Choice of required quantity Checks for missing bags or bottles HECTO CHONDROMETER Hectolitre measuring system A sample falls with the forerunner into the CHON- DROMETER. The contents is weighed with the plastic container on a compact digital balance. Then the determination of the hectolitre weight (kg/hl) of the single cereals is carried out by means of the correction chart. Due to the economic price this instrument is suitable especially for farmer, grain acceptance, universities and field tests. Sturdy construction (stainless steel) Easy handling Handy and independent from the mains Well arranged in a compact suitcase Exact measuring values Good reproducibility Up to five times quicker than conventional mechanical determinations LABORATOry 76 77
REFERENCEs Kombinat Rolny, Kietrz, Polsko STELA MDB-XN 2/17 SU dryer BROCK silos 2x 5 500 t + 2x 850 t pre-cleaners RUV 100 2 x, RVS60 cleaner VOD Jetřichovec, Jetřichovec GDB-TN 1/6 S + 1 000 kw BPS dryer ZD Jiřice MDB-XN 1/13 SU dryer BROCK silos 33 000 t RVS240 cleaner Agra Deštná a. s. GDB-BIO-TN 1/5 S dryer BIN silos 8x 500 t RVS60 cleaner Bonagro Blažovice a. s., Šlapanice MDB-XN 1/6 S + 1 000 kw BPS dryer BROCK silos 16 600 t ZZN Kolín, Pečky MDB-XN 1/13 SU dryer Agrodružstvo Blížkovice MDB-XN 1/7 SU dryer Ing. Miroslav Daňhel, Týn n. Vltavou MDB-TN 1/9 SU BROCK silos 7 700 t Delta 157 cleaner Agro Radovesnice a. s., Radovesnice II MDB-TN 1/10 SU dryer BIN silos 3 940 t RVS100 cleaner Primagra a. s., Milín GDB-XN 1/10 S dryer Ing. Jiří Barták, Velké Chvalovice BROCK silos 5x 1 315 t, 2x 250 t RVS80 cleaner František Janovský, Jarošovice BIN silos 3x 1 000 t RVS60 cleaner 78 79 REFERENCEs
REFERENCEs Moravská Agra a. s., Velké Pavlovice BROCK silos 25 800 t RVS100 cleaner Zemspol Dešná s. r. o., Dešná BROCK silos 4x 2 500 t TAS 204A-4 cleaner Zemědělské družstvo Opařany, Řepeč BIN silos 1 640 t Land Product a. s. Božice BROCK silos 6 600 t MDB-XN 2/6 S dryer ZD Petřín, Nový Petřín BROCK silos 11 600 t Hutchinson grain pump TAS 204A-4 cleaner Rabbit, Chotýšany BROCK silos 43 600 t GDB-TN 1/9 S dryer TAS 154A-4 cleaner Agrodružstvo Jevišovice BROCK silos 10 160 t MDB-XN 1/13 SU dryer Agro 2000 a. s., Smrk BROCK silos 8 000 t SMA 20E cleaner ZEA Hostěradice a. s. MDB-TN 3/12 SU, MDB-XN 2/17 SU dryers BROCK silos 92 320 t 3 cleaners TAS 204A-4 ZD Roštýn, Třešť BIN silos 6x 985 t GDB-N 1/3 dryer TAS 154A-4 cleaner ZD Dolní Újezd u Litomyšle BROCK silos 16 000 t GDB-XN 1/6 S dryer SMA 20 cleaner Agro Měřín a. s., Drnholec BROCK silos 9 200 t MUF 110 dryer TAS 154A-4 cleaner 80 81 REFERENCEs
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