Casting and Manufacturing of Rolls

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1 Casting and Manufacturing of Rolls

2 FP SPOMAX is one of the biggest European manufacturers and suppliers of cast iron rolls for the cereal processing, food processing edible oil and chemical industry. FP SPOMAX is world-wide leader in supply of centrifugally cast iron rolls

3 Rolls manufactured by FP SPOMAX are used for grinding, flaking and cracking products of vegetable and mineral origin. The rolls are used in: milling industry bakery feed milling coffee grinding food industry edible oil industry chemical industry

4 FP SPOMAX supplies rolls to many food processing companies in Europe (e.g. Italy, Germany, UK, Scandinavia) as well as USA, Australia, Far East

5 SHIPMENT PROGRAM Depending on the individual requirements of the clients we supply: fully machined rolls with smooth, corrugated or self-matting working layer and with machined spindles semi finished rolls with ground working layer and with spindles designed for further machining

6 ROLL CASTING FP SPOMAX rolls are produced in our own foundry in one of the most modern centrifugal casting lines in Europe. The chemical composition of each roll is checked during the casting process and each cast is individually numbered.

7 Pouring from furnace

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10 Pouring into centrifugal casting machine

11 Pouring into centrifugal casting machine

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15 Centrifugal casting moulds

16 The method of centrifugal casting enables us to maintain full control over the production process and ensures uniformity of the hard layer of the roll up to 25 mm depth. As a result SPOMAX offers a high quality product which can be used for many years.

17 Pouring into static moulds

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20 ROLL MACHINING After casting, the rolls are cut to the required length and machined according to the individual requirements of each customer.

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22 Roll Spindles/journals

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24 Finished roll blank ready for final finishing

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26 Roll fluting is done using single point fluting machines and each roll is dynamically balanced.

27 SPOMAX supplies the following type of rolls: smooth corrugated self-matting

28 The rolls are used in: milling industry food industry edible oil industry chemical industry They are used for grinding, flaking and cracking products of vegetable and mineral origin. FP Spomax supplies the following type of rolls: smooth, corrugated, self-matting

29 Standard parameters of external (working) layer: thickness: mm hardness: HB, max 580 HB

30 Outer hardened part of roll (ca 20mm depth) Inner softer layer Plug holding the spindle

31 THE SELF-MATTING ROLLS The self-matting rolls are used primarily as milling rolls in the process of grinding of wheat and rye. They replace the so-far used smooth rolls. The self-matting rolls can also substitute finecorrugated rolls on final passages of flour mills.

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33 The working part of self-matting rolls is a centrifugally cast iron sleeve with a special chemical composition and a special microstructure and lowered hardness down to ca. 400 HB. Self-matting rolls developed by SPOMAX are manufactured from a special alloy and have a surface which stays rough during the lifetime of the roll. Special features of the working layer allow it to keep the required roughness for a long time.

34 Self Matting surface remains rough for working life

35 Finished rolls are subject to extensive quality control procedures, in which the measurements are compared with the received order. A certificate containing this comparison is supplied with each roll.

36 FP SPOMAX manufactures rolls for own roller mills as well as numerous devices offered by other manufacturers.

37 We have currently technical details for almost 1000 different types of rolls applied in different industries.

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42 Examples of other castings

43 Roller Mills FMO-7A FMO-8A

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46 Sight glass designed to give optimum distribution of stock across the full width of the feed-rolls Inlet Feed tube/ sight glass Full height level sensor controls feed rolls operation and engage/disenga ge of main rolls

47 Transparent top door lockable - provides access for visual checks Top door Feed rolls Opening panel to check that the feed is correctly spread across the feed-rolls

48 Roll Access To enable easy access to the inside of the roller mill and to facilitate roll changes, the front panel is hinged

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50 Here we see the microprocessor feed roll differential with speed sensor latches for the front panel main roll disc spring tensioning rod Side view

51 Simple, easily removeable feed-roll pack Feed-roll pack Quick release latches allow rapid withdrawal for maintenance and ease of cleaning of interior surfaces

52 Feed-roll pack removal Variable speed motor drive, slides out with the feed-roll pack

53 Structural rigidity is maintained by bolting of main roll bearing housings directly to the fixed base Main Rolls For roll changes, each roll with pulleys and bearing housings can be removed one at a time

54 Positive engage/disengage Positive engaged/disenga ge by pneumatic cylinder ensures that there is no contact with rolls when feed is stopped of brushes/ scrapers

55 Power Supply/Pneumatic components Access to power supply and pneumatic solenoids are enclosed in separate panels

56 Power supply Electrical connections Explosion proof enclosure

57 Microprocessor Siemens microprocessor and emergency stop are clearly visible and accessible

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59 Roller Mills HLW-1 HLW-2

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61 HLW-1

62 HLW-2

63 Plansifters SFA, SFC

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65 Control Sifters SKA

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67 Double deck dry destoner SOK

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69 Sieve Separator SSW with Pneumatic Channel KPO

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71 Scouring Machine MS

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73 Impact detachers Impact pin detachers RZI Infestation destroyer RZE

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75 Drum detachers RK-1-30

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77 Scale LIBRA in the system of production control in the mill

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79 Grain flow balancer SSZ-e

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85 Reverse Jet Filter FRW

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87 Airlock SLU

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89 Blow-through Rotary Valve ZLU

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91 Roots type Blowers DR

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93 Magnetic Separators WM3, WM4

94 WM 3 WM 4

95 Roll Crusher RUD

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