Sunflower

Dehulling

Bhler AG
2014

Oilseeds World Production 2013/2014.

Focus: Sunflower and Rapeseed
Canada

Russia

RS

World No
2
Prod. mio.t :
18
Growth 2012: +29%
Growth 2011: +23%

EU-27
World No
Prod. :
Growth 2012:
Growth 2011:

SF

RS

3
1
8.53
20.8
+21.8% +8.2%
+2.7% +8.9%

Ukraine
USA

SB

China

SB

World No
2
Prod. mio.t :
88.0
Growth 2012: +7.3%
Growth 2011: +32.3%

RS

SB

World No
4
5
Prod. mio.t :
7.0
11.8
Growth 2012:
+2.9% +2.6%
Growth 2011: +7.6% +7.2%

World Wide

Production

Soybeans:
Rapeseed:
Sunflower:
Total oilseeds*:

mio t
284,94
69,97
42,43
502,27

Source: USDA
2 | Bhler | Schlayer| 2014

SB RS

World No
4
3
Prod. mio.t :
12.2
14.2
Growth 2012:
-6.9% +1.3%
Growth 2011: -15.8% +5.9%

India
Brazil

World No
3
4
Prod. mio.t : 54.5
2.7
Growth 2012: +10.5% -13.0%
Growth 2011: +35.9% -22%

SF

World No
1
Prod. mio.t :
11.5
Growth 2012: +27.7%
Growth 2011: +9.5%

World No
1
Prod. mio.t :
88.66
Growth 2012: +7.3%
Growth 2011: +5.2%

Argentina SB SF

SF

World No
2
Prod. mio.t :
10
Growth 2012: +25.6%
Growth 2011: +4.1%

*Includes: Soybeans, Rapeseed, Cottonseed,

Sunflower, Peanut, Palm kernel, Copra

2012
+ 6,2 %
+ 11,0 %
+ 16,5 %
+ 5,8 %

2011
+ 19,3 %
+ 13,6 %
+ 5,3 %
+ 13,8 %

Sunflowerseed Production

Market Outlook
Growth of sunflowerseed production in Europe and Eastern Europe
Demand for high valuable products like animal feed and vegetable oil
due to growth of world population and increase of living conditions
Especially important:
o High yields of oil (low oil residues and low oil losses)
o High content of protein in meal
o Digestibility of meal due to less fiber content

3 | Bhler |

Sunflower Preparation Processes

Sunflower Seed
Dehulling
o beating by impactors
OR
o crushing by corrugated roller mills

Dehulling
Hulls + Kernels (fine)
Separation

Hull Control

Kernels + Hulls

Kernels (fine)
Hull Control
o sifting of hulls and kernels

Flaking

Flaked Seed

4 | Bhler |

Separation
o separation of hulls & kernels
by oscillating sieves
o aspiration of hulls by air

Hulls

Flaking
o flaking of kernels to open oil cells

Dehulling
Key Preparation Technology
Corrugated Roller Mill

Capacities
Sunflower up to 260 - 320 t/24h
Vertical Impact Dehuller

Capacities
Sunflower up to 150 - 180 t/24h

Horizontal Impact Dehuller

Capacities
Sunflower up to 150 - 180 t/24h

* All capacities and performances values are depending on raw material specifications & conditions.
5 | Bhler |

Dehulling
Corrugated Roller Mill

For high capacity multi-seed crushing

- Suitable for multi-seed processes
- High capacity
- Limited dehulling efficiency

The roller miller assures flexible processing of multiseeds.

6 | Bhler |

Dehulling
Working Principles of Corrugated Roller Mill
1
2

level controlled feeding device

Differential4
Speed

feeder allows consistent distribution over

entire roll width

sharp to6sharp
7

permanent magnet removes ferrous particles

in feed
individual roll gap adjustment

1. Inlet bin with product level sensor

2. Pneumatic metering slide gate

scraper knives cleans rolls from seed residues

3. Roll feeder with variable speed

4. Permanent Magnet
5. Product guide plate and roll end sealing
6. Cracking rolls with pneumatic driven roll gap
7. Scraper knife

7 | Bhler | OLCB | Cracking Mill OLCB | 2012

Dehulling
Vertical Impact Dehuller

For efficient multi-seed impact dehulling.

- Suitable for multi-seed dehulling
- Smooth dehulling for low fines content
- Quiet, clean and safe operation

The versatile dehuller adapts to your requirements.

8 | Bhler |

Dehulling
Working Principle of Horizontal Impact Dehuller.
Feeder screw for even feed
Level indicator (top/bottom) avoids choking

Permanent Magnet
Grooved rotor for controlled, fines avoiding
product impact
Dehulling degree adjustment through adjustable
impact cone (spacers)
1.
2.
3.
4.
5.

9 | Bhler |

Product feed
Rotor
Impact cone
Outlet
Dehulling tuner

Dehulling
Especially Suited for Multi-Seed Oil Mills.
Main advantages:
Applicable for dehulling of various oilseeds
incl. sunflower, cotton seed, and soybeans
High process safety due to screw feeder,
magnet and level probes

1. Rotor
2. Wear plates
3. Impact paddles

Continuously adjustable screw and rotor speed

allow perfectly controlled process
Alternative impact cone surface characteristic
(smooth, fluted) for optimized dehulling
Efficient especially with higher moisture
content

10 | Bhler |

Impact cone characteristics

Smooth: Sunflower
Fluted: Soy, cotton seed

Dehulling
Horizontal Impact Dehuller

For state-of-the-art sunflower dehulling.

- Smooth dehulling for low fines
- Long machine lifetime
- Easy maintenance of key parts

Applied in the sunflower seed processing industry exclusively.

11 | Bhler |

Dehulling
Working Principle of Horizontal Impact Dehuller.

Feeder roll with integrated frequency converter

5

Magnet
3

Wear resistant and adjustable impact chest

Only applicable for sunflower seeds

5
4
1.
2.
3.
4.
5.

12 | Bhler |

Product feed
Rotor
Impact chest
Outlet
Dehulling tuner

Dehulling
Simple Way of Dehulling.
Main advantages:
Simple and fast adjustment of impact chest
and thus excellent dehulling quality

Permanent magnets

Impact chest adjustment

Impact rotor

Impact chest

No aspiration required
Simple and easy accessible and
exchangeable wear parts
Efficient especially with lower moisture
content

13 | Bhler |

Dehulling
System Comparison.

Corrugated
Roller Mill

Vertical
Dehuller

Horizontal
Dehuller

Dehulling Efficiency

++

++

Sunflower Suitability

++

++

Other oilseeds

++

N/A

End Product Quality

++

++

Integrated Safety Features

++

Aspiration

Yes

Yes

No

Throughput (t/h)

++

Efficiency (kWh/t)

++

Space requirement

++

++

++

Serviceability

* ++ very good;

14 | Bhler |

+ good; 0 acceptable; N/A not applicable

Dehulling
Technical Datas - Overview.

Corrugated
Roller Mill

Vertical Dehuller

Horizontal
Dehuller

Dimensions (mm)
Length
Width
Height

2.920
1.900
1.130

2.110
550
1.820

2.923
2.003
1.925

Rotor / Roll diameter (mm)

Rotor / Roll length (mm)

300
1.600

600
-

800
2.150

Aspiration needed (m3/min)

20

15

Motor power (kW)

Feeder drive
Main drive

0,75
18,5

0.37 (FC optional)

15-22 (FC optional)

0.33
18

Weight (kg, net)

3.690

825

2640

16

260 320
500 - 800
230 260

150 - 180
120 - 150
120 - 150

150 - 180
-

Impact Dehuller

Beaters / Throw paddles / Rolls

Throughput (t/24h)
Sunflower
Soybean
Cotton seed (max. 4% lint)

15 | Bhler |

Separation
Hull Separator

Efficient sifter for hull separation.

-

Optimal separation of oilseed kernels from hulls

High throughput capacities
Easy operation and maintenance
Designed especially for oilseed separation

Applied in the oilseed processing industry for the dehulling of sunflower seeds and soya.

16 | Bhler |

Separation
Key Preparation Technology

Hull Separator SMA 203-3 OL

1
1. Proven main hull aspiration system
Easy adjustable, powerful suction nozzles

2
2. Proven post hull aspiration system
Multi-tunable aspiration channel
Large control window for optimal setting

17 | Bhler |

Separation
Working Principle and Technical Data
Cleaning
backflow of undehulled seed
coarse hulls

Impact Dehuller

fine hulls

fine seed to flaker

dehulled seed to 2nd stage or to flaker

18 | Bhler |

hulls to sifter

Separation
Working Principle and Technical Data

backflow of undehulled seed

Impact Dehuller

fine seed to flaker

hulls to hull control

dehulled seed to 2nd stage or to flaker
19 | Bhler |

Sunflower Preparation Processes

Objective

reduction of fiber content in meal by hull removal

increase of final protein content
highest oil yield

Different Dehulling Processes

2- stage Dehulling

Hull Removal from 26% to 10%

1- stage Dehulling

Hull Removal from 26% to 14 12 %

Differentiation through the rest of hull content and amount of kernel loss by
efficient hull controls
* additional 2,5-3 % botanical oil content in hulls
20 | Bhler |

Sunflower Preparation Processes

2- stage Dehulling with Total Hull Control
10% rest hull
1,0-1,2% oil loss with hulls*

5
4

Separation
* additional 2,5-3 % botanical oil content in hulls
21 | Bhler |

Hull Control

1.
2.
3.
4.
5.
6.

Dehuller
Separator
Filter/Cyclone
Hull Sifter
Hull Drum Sieve
Hull Separator

Sunflower Preparation Process.

1- stage Dehulling with Total Hull Control

12% rest hull

0,9-1,1% oil loss with hulls*

dehulling results
low kernel/ oil losses

high investment
1
5
2

Separation
* additional 2,5-3 % botanical oil content in hulls
22 | Bhler |

Hull Control

1.
2.
3.
4.
5.
6.

Dehuller
Separator
Filter/Cyclone
Hull Sifter
Hull Drum Sieve
Hull Separator

Sunflower Preparation Process.

1-stage Dehulling with Partial Hull Control

14% rest hull

1,0-1,2% oil loss with hulls*

Separation
* additional 2,5-3 % botanical oil content in hulls
23 | Bhler |

Hull Control

1.
2.
3.
4.

Dehuller
Separator
Filter/Cyclone
Hull Sifter

Sunflower Preparation Process

Yields
SUNFLOWER INPUT SPECIFICATION
Moisture content
Oil content
Crude fiber content

Protein content
Hull content
Impurities

8,00 %
43,00 % NS
17,50 % NS

18,00 % NS
26,00 % NS
< 1,00 % NS

YIELDS AFTER DEHULLING

1 stage

1 stage

DEHULLING

2 stage

partial

total

Rest hull content in dehulled fraction

10 %

14 %

12 %

26 %

Capacity prior to dehulling

Capacity prior to expeller pressing

no dehulling

100 t/24h
80 t/24h

100 t/24h
84 t/24h

100 t/24h
82 t/24h

100 t/24h
100 t/24h

18 t/24h
0,21 %
37 t/24h
44,5 %
19 %
1,0 %
34 t/24h
7 t/24h

14 t/24h
0,16 %
41 t/24h
41 %
23 %
1,0 %
33 t/24h
8 t/24h

16 t/24h
0,17 %
39 t/24h
42,5 %
22 %
1,0 %
33 t/24h
8 t/24h

0.0 t/24h
0.0 %
56.2 t/24h
31.4 %
29.3 %
1,0 %
30 t/24h
11 t/24h

YIELD
Total hulls removed
Additional oil loss*
Extraction meal
Protein content
Crude fiber content
Oil content
Expeller crude oil
Extraction crude oil

* based on seed input; all figures determined with Bhler Oil Balance calculation
24 | Bhler |

Sunflower Preparation Process.

Performance Figures
SUNFLOWER INPUT SPECIFICATION
Moisture content
Oil content
Crude fiber content

Protein content
Hull content
Impurities

8,00 %
43,00 % NS
17,50 % NS

18,00 % NS
26,00 % NS
< 1,00 % NS

Dehulling Stages

2-stages

1-stage - partial

1-stage - total

Rest Hull Content

10 %

14 %

12 %

Protein Content

44,5 %

41%

42,5 %

Loss of Oil

1,2 1,0 %

1,2 1,0 %

0,9 1,1 %

0,2 - 0,3 %

0,15 0,2 %

0,17 0,2 %

based on Hulls

Loss of Oil
based on seed input

25 | Bhler |

Flaking is Key in Achieving Low Rest Oil in Meal.

State of the art features

Flake thickness adjustment during operations
Easy access for regular maintenance
Correct roll type and surface

Optimal Sunflower throughput

(at 0.4mm flake thickness, cold, 8% H2O)
capacities of approx. 400 t/24h

26 | Bhler |

www.buhlergroup.com

27 | Bhler |

Bhlers High Performance Flaking Mill OLFB.

Bhlers state-of-the-art flaking mill.

High performance flaking mill

Flake thickness adjustment during operations
Compact and efficient
Easy maintenance, safe operation