A new flaker from Bühler for oilseed processing: OLFC

Image: Bühler Group

The Swiss-based technology group Bühler has unveiled its new OLFC flaker system, used to flake oilseeds such as soya, rapeseed and sunflower prior to extraction. The new machine combines improvements in mechanical durability, vibration control, roller life, energy consumption, maintenance and automation.

In oilseed processing plants, flakers are among the pieces of equipment that operate continuously. As each OLFC is capable of processing up to 500 tonnes of product per day, the reliability of the equipment is crucial for production continuity. Furthermore, the size, thickness and consistency of the flakes are among the factors that influence the efficiency of the subsequent oil extraction stage.

Reinforced mechanical structure

As part of development work carried out in collaboration with customers, Bühler engineers identified components subject to high mechanical stress and implemented various structural reinforcements in the OLFC’s design. These modifications include a reinforced base frame, cast bearing unit components, larger-diameter pulleys, reinforced roller shafts and a revised motor connection.

This design aims to reduce machine vibration by up to 25 per cent compared to previous models. Lower vibration can contribute to equipment stability and the management of maintenance processes in continuously operating plants.

The OLFC utilises rollers with a diameter of 820 mm. With the usable diameter also increased, the service life of the rollers is extended by 150 per cent compared to previous designs. This is intended to reduce the frequency of roller changes and maintenance-related downtime.

The machine’s enhanced hydraulic system provides protection against sudden pressure surges that may occur, for example, when foreign objects enter the equipment.

The timing belt used in the OLFC’s power transmission can reduce energy consumption by up to 4 per cent compared to previous models. The auxiliary drive system facilitates servicing by enabling the rollers to rotate at low speed during grinding. According to Bühler, saving two hours in maintenance time can help maintain a processing capacity of approximately 41 tonnes for a single flaker.

The new automation system displays the machine’s operating status in real time via a touchscreen. Thanks to integrated sensors, performance data is monitored, whilst data from multiple flakers can be compared to identify maintenance requirements at an earlier stage.

Long-term performance trends can be monitored via Bühler Insights, and maintenance planning can be carried out based on this data. This approach aims to make more effective use of process data from equipment in plants where the number of experienced operators is declining.

OLFC was developed based on feedback from customers in North America, Europe and China. One of the systems, whose prototypes were tested at two soya processing plants in the US, has been operating under real production conditions since October 2023.

The validation process in a real production environment and user feedback from plants across different regions demonstrate that practical experience has played a significant role in the development of OLFC. The system stands out as a contemporary application of Bühler’s expertise in engineering, process technology, automation and digital monitoring within the oilseed processing sector.