Milling

Efficiency and
Mill Setting

Presented By:-
Sarvesh Mishra
FOR GETTING THE IDEAL MILLING RESULTS IT IS
IMPORTANT TO STUDY AND CONTROL THE FACTORS
GOVERNING THE MILLING AND IMPLEMENTS NEW
MILLING TECHNIQUES.
The following factors are important in the
Milling
1) Equipment and System Design
2) Cane Feeding
3) Cane Preparation Level
4) Primary Extraction
5) Roller Grooving
6) Mill Speed
7) Mill Setting
8) Hydraulic Pressure
9) Imbibitions
10) Design Features and Workmanship of the Mills
11) Skill and the Operating Techniques
12) Plant Maintenance
13) Crushing Rate v/s Mill Extraction
14) Number of Mills/Roller in the Tandem
1. Equipment and System Design
 Design of each and every equipment plays an
important role in smooth functioning of plant and
achieving targeted efficiency.
 Few critical equipments will be discussed further.

 Equipment Design
 Cane Chopper
 Cane Shredder
 Mills

 Cane Chopper Functions

 To chop the cane into small pieces (25-30 cm long).
 To act as a metering device to give controlled
feeding to succeeding devices.
 Cane Chopper Design Requirement
 Swing diameter shall be in the range of 1800-2000
mm.
 Tip speed shall be in the range of 27-30 m/sec.
 Knife pitch shall be in range of 80-100 mm.
 Cane cutting shall be about 65%.
 Operating speed shall be in the range of 270-300
rpm.
 Installed power – 12-15 kw/tfh
 Location shall be near to start of inclination on cane
carrier.
 Metering type hood shall be installed.
 Direction of rotation shall be reverse to cane flow.
 Cane Shredder Function
 To open the cells to the extent possible.
 Cane preparation should be long fibrous.

 Cane Shredder Design Requirement

 Tip speed > 88 m/sec
 Anvil wrap angle about 90⁰
 Hammer weight about 23 kg with domite tip.
 Hub design shall be star (quadruple) type having 8
rows.
 Installed power-50 kw/tfh
 Milling Technologies
 Conventional three roller mill
 Two roller mills

 Milling Design Requirements

 Lower apex angle (for conventional mill).
 Free floating hydraulic system
 Easy to accommodate higher size UFR
 Effective juice drainage (Journal center should be
enough to have sufficient gap between headstock
and roller shell.)
 Easy accommodation for feeding device.(GRPF/ TRPF)
 Smooth adjustment of mill setting.
 Easy assembling and dismantling.
 Conventional Mill Type

 Vertical Set Mill

Apex angle 72 to 74 deg.
Less power consumption

 Horizontal set mill

Apex angle 75 to 78 deg.
Highest power consumption

 Inclined set mill

Apex angle – 74 to 76 deg.
Medium power consumption
2. Cane Feeding
Erratic loading on chopper, cutters and
fibrizer/shredder
Jamming at chopper
Donnelly chute jamming
Higher mill operating speed
Lesser extraction

Maintaining Uniform Feeding

Consistent level in cane carrier
Optimum design of cane chopper hood.
Optimum loading on cane chopper.
1st mill at almost at fixed speed to achieve desired
crush rate
3. Cane Preparation Level
Preparatory index +90
Long fibre
Minimal power consumption
5.5 – 6 kw/tch (45 kw/tfh)

Advantages of Higher Preparation

Higher primary extraction
Increased reduced mill extraction
Less power consumption on mills
Less wear on rollers
 Cane Chopper
i) Nos. : 1

ii) Nos. of blades & Pitch : 48 Nos. and 90mm

ii) Swing dia : 1600 mm

iv) Drive : 500 HP, 390 RPM

v) Clearance : 400 mm

vi) Direction : Reverse

vii) Tip Speed : 32.15 m/s

ix) Pulley Big Size : 752 mm dia

x) Pulley small size : 490 mm dia

Cane Chopper
 Head on Cutter
a)Qty. - 01 nos
b)No. Of Knives - 60 nos
c)Pitch - 72 mm
d)Swing diameter - 1916 mm
e)Drive Motor - 503 Hp x 2 Units
f) Speed - 590 rpm
g)Tip Speed - 59.16 m/s
h)Clearance - 200/100/50 mm
i) Direction - Forward
Head On Cutter
Knife of cutter & chopper
 SHREDDER
Swing Type Hammer Shredder
Swing dia - 1524 mm
Width - 2300 mm
Nos of hammers & Pitch - 147nos. & 90mm
Hammer material - IS:2062 with Domite tip of 80mm x 56 mm x 45 mm
Drive - 804 hp x 2 units
Wrap Angle - 76° degree,
Anvil Pocketed type hard faced - 50 BHN (min)
Operating Speed - 989 RPM
Tip Speed - 78.91 M/s
Direction of rotation - Forward to cane carrier
Spherical roller bearing with adapter sleeve SKF make, At one End 23056
CCK/C3W33 with adapter sleeve and at another end C- 3056 K/C3 CARB .

Oil cooler with one stand by cooler and Pump having cap. 200 litre.
SHREDDER HUB
ASSEMBLY
CANE DISTRIBUTER
(REVERSE DIRECTION)

CANE BELT

HAMMERS
WITH DOMITE
TIPS

ROTOR

ANVIL PLATE

SHREDDER
SHREDDER DISTRIBUTOR
Shredder Hammer Shredder Rotor
 Preparation Index
Cane preparation is measured in terms of preparation index (P.I),
which is the degree of finesse or percent of open cells, when cane
prepared its bulk density increases from 200 kg/m 3 to 700
kg/m3
The minimum value of preparation index 60% up to 90%,this
value depends on the various devices used
Preparatory Index
Before Shredder – 68 to 70
After Shredder – 88 to 90
The degree of achievement of preparation or the stat of
disintegration of cane is expressed by the percentage of pol in the
open cell or preparatory index. (P. I.). It is measures in laboratory
by taking average sample of prepared cane two parts of the
measured samples are (1) leached (2) disintegrated or digested in
measured samples of water and respective pol reading are noted.
 RELATIONSHIP BETWEEN BULK DENSITY AND
PREPARATORY INDEX AT 15% FIBER

B.D. (kg/m3) P.I

400 44.5

450 52.85

500 61.25

550 69.65

600 78.05

650 86.45

700 94.85

Pol extracted by leaching

Percentage of P. I. = x 100
Pol extracted by disintegration
 Achievements during
seasons 2022-2023
Total crushing -
5424381
Average Crushing (incl. stoppage) -
37217
P. I. Avg
- 87.08
Primary Extraction (Juice Basis) -
71.02%
Capacity Utilization -
74.46%
Mill extraction -
97.34%
Imbibition % cane -
48.43
Imbibition % fibre -
354.02
Pol -
1.30 %
Moisture -
Method of utilizing knives

Maxwell' distinguishes two types of knives,

according to the role which is demanded of them :
(a) The leveller knives which are required mainly
to even out the layer of cane . They are arranged
to work with a high clearance and in consequence
leave a large proportion of uncut cane.
(b) The cutting knives . This second effect is
sought only when two sets of knives are installed:
the first, at the bottom of the sloping portion of
the carrier, would play the role of chopper, the
second immediately after the first or at the head
of the carrier, would then have the function of
finishing the complete disintegration of the cane,
and would be used at a very small clearance.
 Tramp Iron Separator
 Generally, a number of pieces of steel and cast iron pass through mill in
the season, like sling hooks, broken pieces of sling, bolt & nuts, broken
knife, broken angle & channel from truck & trolley. The amount of tramp
iron may be reduced by taking precautions in the loading and unloading of
the cane by supervising.
 The pieces of steel are the most dangerous, some times people at the mills
hear the abnormal noise at Shredder & first mill which damage roller
teeth & groove, mill is then stopped. This is caused by entrance of foreign
material which is later found & removed.
 To avoid such type damage and loss, an equipment called “Tramp Iron
Separator” is installed for removing the iron pieces.
 The device is an electromagnet contained inside a rectangular box
supported at the last belt conveyor before entry to the first mill, and
covering the full width of belt conveyor. The holding range is max.400mm
(ACM gap -375mm)
 This device consumes about 7 kw with nearly 100% efficiency for large
pieces to pick-up. This little power gives efficient protection of entire mill
roller.
Tramp Iron Separator Cane Equalizer
 Juice Extraction
There are two processes for extracting juice from cane:
1- Milling,
2- Diffusion.
Milling : -
Juice extraction by milling is the process of squeezing the juice from
the
cane under a set mills using high pressure between heavy iron
rollers.
Those mills can have from 3 up to 6 rolls; every set of mills is called a
tandem mill or mill train. To improve the milling extraction efficiency,
imbibition water is added at each mill. Hot water is poured over the
cane just before it enters the last mill in the milling train and is
Re-circulated up to reach the first mill. Milling trains typically have
four,
five or six mills in the tandem.
Diffusion :-
In the sugar factory, diffusion is therefore the
phenomenon by which the
cells of the beet or the sugar cane, immersed in water or
a solution of
lower concentration then the juice which they contain,
give up to that
water or to that solution a part or all of the sugar forming
the excess of
concentration of their juices. At this point the
concentration of
sucrose in the cane is higher than the concentration of
sucrose in the
dilute juice just mentioned and so sucrose diffuses from
the cane to the
Juice.
4. Primary Extraction
The greater the extraction of sugar in the first mill the less
difficult in the
task left to the following mills to recover more sugar by the
trouble some
step of wet extraction and better is the overall extraction of
the tandem.

It is proved that a gain of 1% in primary extraction gives a

gain in total
extraction of 0.12% in 12 roller tandem, 0.10% in 15 roller
tandem and
0.09% in 18 roller tandem.

It is therefore, necessary to observe first mill extraction

carefully and
report the figure in chemical control reports.
6. Mill Speed

The mill speed can be recognized in two ways

a) As peripheral speed of the rollers i.e. the linear speed of a
point at the mean diameter of roller. It is generally expressed
in m/min.

b) As speed of rotation of rollers, i.e. the no. of revolutions

which they make in unit time. It is generally expressed in
R.P.M. Relation between two speeds
V = Pi x D x n

c) Lower the speed of the mill, the bagasse in the mill

have more retention time for effective juice drainage.

d) Lower speed of roller improves co-efficient of friction and it

will have better grip on bagasse reducing the slippage.
7. Mill Setting Requirement
Settings should be appropriate to run the mill at lowest
possible speed.
Trash plate heel angle should be in the range of 28-30 deg.
Crown pinion range shall be suitable for operating centers.

Mill Setting Formula

Capacity X Fibre% Cane

= --------------------------------------------------------------------------------------------------
Suface Speed of
Roller x Roller length x Fibre Index

Feed opening = Discharge opening x mill ratio

Trash plate opening = Feed opening x trash plate ratio

 MILL ROLLER & GROOVING
The improved cane preparation and increasing crushing, provision of
high imbibition water have increased juice quantity in the mill. If
this increased juice is not drained effectively, then it affects the
mill extraction adversely and will demand extra hydraulic load
increasing the power demand in the mill. The pressure feeding
equipment's, lotus rollers and differential are used in the mill to
ideal with this increased juice. Out of these differential grooving
is discussed in detail.

Expected functions from grooving are as under

a) To press and squeeze the prepared cane in 1st mill and bagasse
in other mills for juice extraction.
b) To drain the juice effectively from mill.
c) To mill the bagasse further to get the uncut juice cells broken to
help to increase the extraction in the following mill.
d) To drive the bagasse through the mill effectively.
Factors Increases Re-absorption in Milling Tandem

 Poor cane preparation

 Higher surface speed
 Higher hydraulic loading than required
 Inefficient juice drainage
 Roller polishing
•Fibre Index
Another quantity necessary for the study of milling plant is
being passed through the delivery opening of a Mill. For this
purpose, the weight of Fibre passed through the opening in
unit time is related to volume by that opening when operating,
in the same unit of time.
So Fibre Index is weight of Fibre per unit escribed volume of
that mill.
Unit of Fibre Index is Kg/meter cube or lbs/[Link]

•Escribed Volume : It is the volume generated by the

opening between two rollers.
Surface speed x Length of roller x Work opening of mill

•Work Opening :
Work opening = Mill setting + Lift of Mill
 Data Chart
Mill
Mill No.2 Mill No.3 Mill No.4 Mill No.5
No.1
Crushing (TCD) 4300.0 4300.0 4300.0 4300.0 4300.0

Crushing (TCH) 179.2 179.2 179.2 179.2 179.2

Fibre% cane 16.0 16.0 16.0 16.0 16.0

Total Fiber ([Link] Min.) 477.3 477.3 477.3 477.3 477.3

Motor RPM 700.0 650 650 575 600

Overall reduction 0.00421 0.00421 0.00421 0.00421 0.00421

RPM 3.0 2.75 2.75 2.5 2.55

UFR /Mill ratio 1.10 1.10 1.10 1.10 1.1

TUFR Dia 1090.0 1090.0 1090.0 1090.0 1090.0

TUFR PCD 1040.0 1040.0 1040.0 1040.0 1040.0

TUFR RPM 3.3 3.03 3.03 2.75 2.8

Roller Shell length 1980.0 1980.0 1980.0 1980.0 1980.0

 Roller Details
Mill No.1 Mill No.2 Mill No.3 Mill No.4 Mill No.5
Top Roller
OD 1115.0 1109.0 1090.0 1130.0 1130.0
Depth 45.0 45.0 45.0 31.0 45.0
PCD 1070.0 1064.0 1045.0 1099.0 1085.0
Groove Angle 50° 50° 50° 50° 50°
Pitch 50 50 50 35 50
Feed Roller
OD 1105 1075.0 1085.0 1097.0 1124.0
Depth 67.0 67.0 67.0 40.0 67.0
PCD 1038 1008.0 1018.0 1057.0 1057.0
Groove Angle 35° 35° 35° 35° 35°
Pitch 50 50 50 35 50
Discharge Roller
OD 1124 1130.0 1100.0 1095.0 1130.0
Depth 51.0 51.0 51.0 31.0 51.0
PCD 1073 1079.0 1049.0 1064.0 1079.0
Groove Angle 45° 45° 45° 45° 45°
Pitch 50 50 50 35 50
 Calculation Base
We will calculate setting for our first mill with the following data:
 Crush Rate : 180 TCH
 Fibre : 16 % on cane
 Mill rpm : 3.0 at 715 rpm of motor
Mean Roller Dia= (1115+1105+1124)/3 mm = 1.115 mtr.
 Roller length : 1980 mm = 1.980 mtr.
Fibre loading ( should be ) : 23 – 25 kg / m²
 Mill 1 Mill 2 Mill 3 Mill 4 Mill 5
 Fibre index : 560 650 750 850 950

First of all we will calculate Fibre loading in kg/m²

Fibre loading ( q ) = TCH x fibre % cane x 1000

60 x π x n x D x L
q= 180 x 0.16 x 1000
60 x 3.14 x 3.0 x1.115 x 1.980
q = 23.08 kg / m²
 fibre index
= 23.08 x
1000
560
= 41.2 mm
Lateral Lift = 40.8 x .20 = 8.24 mm
Angular Lift = Lateral Lift / Cos (75.7/2)°
= 8.24/Cos 37.85°
= 10.43mm
Discharge Work Opening at Rest = 41.2 - 10.43
= 30.77 mm
Feed work opening = Discharge work opening x mill
ratio
= 41.2 x 2.0
= 82.40
Feed work opening at rest = 82.40 – 10.43
= 71.97mm say, 72.0
mm
Trash Plate Opening = Feed work opening x trash plate ratio
= 82.4 x1.7
= 140.08
Trash Plate Opening at Rest = 140.08 – 8.24
= 131.84 mm
SETTING CALCULATION OF T.U.F.R :
Fibre loading = TCH x fibre %cane x 1000
60 π x n x D x L
where,
fibre % cane = 16 %
n = T.U.F.R rpm
D = T.U.F.R roller diameter (1.090
meter)
L = T.U.F.R roller length ( 1.980 meter)
T.U.F.R rpm is 110 % of mill top roller rpm.
Therefore, T.U.F.R rpm is 1.1 x 3.0 = 3.3

Average roller rpm ( n ) = 3.0 + 3.3 / 2

= 3.15 rpm
So, fibre loading ( q ) = 180 x 0.16 x 1000
60 x 3.14 x 3.15 x 1.090 x 1.980
= 22.48 kg/m²

T.U.F.R work opening = q x 1000

ø
= 22.48 x 1000
88.0
= 255.45 mm
CONCLUSION
Almost all the methods are useful as a guideline
only and figure calculated are near
the requirement. The minor adjustment in the mill
setting are required to be done during running
to suit the site condition with the help of mill
test and ideal brix curves.
 ACTUAL MILL SETTING AT REST
2022-23
Mill
SN 2022-23 No.1
Mill No.2 Mill No.3 Mill No.4 Mill No.5

Apex Angle 75.7° 75.0° 76.0° 76.9° 76.1°

Discharge 26 24 22 20 18

Feed 52 49 47 43 41

Trash 97 93 92 86 82

UFR (Teeth to Teeth) 145 140 135 130 125

Donnelly chute (Top) 475 410 390 365 365

Donnelly chute (Bottom) 511 450 430 410 400

Trash Plate Slope 5.7% 5.15% 5.8% 5.1% 5.2%
Heel Clearance 53 44 62 62 43.5
TUFR to TOP Centre 80 115 152 129 138
IDENTIFYING MILL SETTING PROBLEMS
If power consumption is more for a particular crush rate
from
other factories or if the trash plate on inspection is found
to
heavily wear, it means trash setting was too high.
If the mill snores(chatters) it means that the toe of the
trash plate is set to low.

•Mill squirting :
Some times wet bagasse or water is sprayed out from the
mills and it happens when trash plate clearance is less.

•Mill flooding :
This happens when the juice drainage area is less in the
grooves or the close work opening.
•Donnelly chute :

 This must be run 2/3 full to give

pressure feeding to mills.
Donnelly Chute level should be marked
from underfeed roller center as
reference and it should in range of
1.5mtr to 2 mtr.
If we are not getting proper RME ,
proper Primary Extraction or proper
bagasse pol we need to readjust our
mills.
• Mill Choking –
1. This is either due to bad settings of mills,
the feed opening to small or to large , the
trash plate badly placed or poorly adjusted
at feed roller the space at the heel of the
plate too small or has lifted and bent
towards back.
2. Could be due to new polished rollers,
smooth rollers surface. OR rollers too small
in dia, too worn with rounded teeth.
3. Could also be because of excessive
imbibiton or imbibition water too
hot when mill slips . If bagasse is not
delivered in continuous flow from the mills
or if mill slips with grumbling sound
indicates low trash plate settings.
 Juice Imbibition
Definition:-
Imbibition and juice maceration plays important role in
achieving better mill extraction. Imbibition water dilutes the
juice in bagasse and reduces it viscosity. The characteristics
of low viscosity of juice increases the flow of juice through
bagasse. The hot water further helps in reducing the
viscosity of the juice. However higher temperature of water
sometime leads to slippage of bagasse in the mill. The
higher imbibition water is restricted due to capacity of
boiling house and availability of steam and therefore it
restrains to increase crushing rate.
It may please be noted that higher imbibition water do not
increase the moisture in the bagasse.
 But inadequate juice drainage, low compression, higher
speed, improper cane preparation are the main reasons for
increase in moisture of bagasse.

There are methods adopting now a days:-

Simple flash imbibition by gravity
Pressure imbibition by pump
Simple Imbibition:- In this procedure add water to the
bagasse after each mill, this system consumes much water
Compound Imbibition:- In this procedure, the dilute
juice obtained from the last mill and sent back before the
preceding mill and again this juice returned before the
previous mill
 Rotary Screen

Screen juice
tank
Hot
Water
temp 65°
to 75°

Mill – 5
Mill – 1 Mill – 2 Mill – 3 Mill – 4

5th Mill Juice

1st Mill Juice 2nd Mill Juice 3rd Mill Juice 4th Mill Juice
Advantages with hot water imbibition
 Optimum temperature of hot water 65oC to 70oC.
 Power to pressure the fibre will be less (60o to 65oC)
 Efficiency of imbibition increases these by extraction
increases.
 The mixed juice temperature also increases by 10o to
15oC these by the exhaust requirement reduce by about 2
to 2.5%.
 Bagasse temperatures also increase to about 45o to 50oC.
 As it travels upto the boiler about 1% of moisture will be
evaporated.
 These by reduce the moisture 1% by 1% and GCV
increased by 45 – 70 Kcal/Kg.
Disadvantages with hot water imbibition:
• More wax soluble in juice, which gives problem in clarification or
filtration.
• Mill capacity slightly reduces because of roller polishing i.e. gripping
action is reduced.
• Last mill bearing temperature increases.
• Range of imbibition efficiency is around 60 to 70% .
 Plant Maintenance

Maintenance Strategy
Integration of complementary techniques to meet the goals of
optimum equipment reliability and availability for the
least maintenance and operating cost.

APPROACH TO MAINTENANCE :-

1. Unplanned.

2. Planned.
i) Reactive Maintenance
ii) Preventive Maintenance
iii) Proactive Maintenance
iv) Predictive Maintenance
Benefits of a Planned Maintenance System

 Reduce the size and scale of repairs

 Reduce downtime
 Increase accountability for all cash spent
 Reduce number of repairs
 Increase equipment’s useful life
 Increase operator, mechanic, and public safety
 Increase consistency and quality of output
 Reduce overtime
 Increase equipment availability
 Reduce number of backup and standby units
 Increase control over parts and reduce inventory level
 Improve information available for equipment specification
 Lower maintenance costs (better use of labour /materials)
 Lower overall cost /product unit
 Reactive Maintenance (RM)

Also known as breakdown, run to failure maintenance.

Maintenance is performed only after the equipment fails. “If it
isn't broke, don’t fix it” “When it breaks, we’ll fix it”

 Preventive Maintenance (PM)

Also known as Time-based or Interval-based Maintenance.

Maintenance activities are performed on a calendar or
operating time interval basis to extend the life of the
equipment and prevent failure.

 Predictive Maintenance (PdM)

Also known as Condition- Based Maintenance.

Uses non-intrusive testing techniques, visual inspection and
performance data to assess machinery condition.
 Proactive Maintenance (PAM)

Improves maintenance through better design, installation,

maintenance
procedures, workmanship, and scheduling.
Employs the following basic techniques to extend machinery
life:

– Specifications for new/rebuilt equipment

– Precision rebuild and installation
– Failed-Part Analysis (FPA)
– Root-Cause Failure Analysis (RCFA)
– Reliability Engineering
– Rebuild certification/ verification
– Age exploration
– Recurrence Control
Mill Assembly
Mill With Inter Rake Carrier
 TUFR
(Toothed type Under Feed Roller)
 Key Parameter for
determining Milling
efficiency
 Constant Feeding  Lift and free play of Top roller
 Over loading of preparatory bearing
devices  Hydraulic load
 Donnelly Chute level  Juice drainage / flooding
 Mill Setting & operating rpm  Maceration % Cane
 PI  Cleaning of messcheart grooves
 Ratio of Discharge, feed &  Frequent change in crush rate
Trash plate
 Bearing condition
 Proper & effective maceration
 Temperature of Maceration
 Recirculation of Juice & kush-
kush
 Extraction
 Primary Extraction :- pol extracted by 1st mill dry crushing.
e₁= 1 - S₁ f
S₀ f₁
Where:- e₁ = Primary juice extraction , S₁ = Pol % primary juice
S₀ = Pol % cane , f = fibre % cane , f₁= fibre % 1 st mill
bagasse

 Mill Extraction :- Total pol extraction of the tandem.

e= Pol in mixed juice % cane × 100
Pol % cane

 Reduced Mill Extraction:- Total pol extraction of the

tandem
on standard fibre %
cane (12.5 )
E ₁₂.₅ = 1 – ( 1 - e ) ( 1 – f )
7f
 Brix Curve
One of the best methods of controlling the milling plant is to
construct a graph of the brix of the juice from the successive Mills

03/01/202
Mill 1 Mill 2 Mill 3 Mill 4 Mill 5
3

Feed 18.57 6.85 3.35 1.6 0.88

Discharge 18.37 7.95 3.95 2.2 1.19

Composite 18.47 7.25 3.67 1.9 1.05

Idle 18.47 5 1.49 0.4 0.09

 Juice flow= 200
Tandem HCM1
Cu.M/Hr.
Imbibition %
47.18
Cane
Dated : 03.01.2023
Fibre % Cane 13.54
Mills Feed Extraction Discharge
Extraction
Mill - 1 50 50.00
Mill - 2 63.64 36.36
Mill - 3 46.67 53.33
Mill - 4 50.00 50.00
Mill - 5 45.16 54.84

Mill - 1 Mill - 2 Mill - 3 Mill - 4 Mill - 5

Bagasse Pol
% 7.74 4.86 3.58 2.02 1.29
Bagasse
Moist. % 54.40 52.90 51.70 50.10 47.60
Pol %
Extraction 5.48 12.6 5.48 12.6 5.48
Moisture
%
Extraction 2.88 1.5 2.88 1.5 2.88
 Control Down time on Milling
The down time can be reduced by proper repair & maintenance, with
safe operation of Mill.
Steps to Control the down time
 To adopt preventive maintenance schedule
 Staff training to take main steps to prevent the failure.
 Sharing of Knowledge/Experience through discussion
 Close watch of each equipment.
 Share problems observed in the shift, with each other,
 Routine checking of the equipment i.e.
 Loosing of cane carrier bolts.
 Bending/damage of cane carrier slates.
 Wear and tear of cane carrier chain links, pins, bushes & rollers.
 Bending of rake elevator & inter carrier rakes
 Loosing of IRC rakes holding bolts.
 Loosing of pin/ split pin of the chain of IRC
 Checking of all preparatory units bearing temperature
 Do not take any problem lightly & do not carry on it longer
Causes of Milling Losses & Control
 Poor cane feeding
 Cane slippage
 Leakage from pump glands
 Leakage from juice trough
 Flushing from back side of mill
 Chute level became empty
 Juice flooding from Top Roller
 Un effective maceration
 Mills rpm & variation in mill rpm
 Load variation of Mills
 Hydraulic loads
 Temperature of Maceration water
 Inter mixing of imbibition juice
 Moisture & pol of mill
 Mills bearing temperature