Internship Report

ON-JOB TRAINING (OJT)

MUHAMMAD IMRAN
SERIAL NO: 16

DEHKAN FLOR MILLS (PVT) LTD.

RAHIM YAR KHAN
KHWAJA FAREED UNIVERSITY OF ENGINEERING AND
INFORMATION TECHNOLOGY
RAHIM YAR KHAN

CHEMICAL SUPERVISOR
BATCH 1: 15 FEB 2020- 15 JULY 2020

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 Submitted to
Eng. Tahir Fazal
In complete fulfillment of the requirement for the certificate of
Chemical Supervisor
By
Mohammad Imran
Serial no. 16

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Table of Contents
1 Introduction ............................................................................................................................. 4

2 Wheat Composition ................................................................................................................. 5

3 Treatment of Flour ................................................................................................................... 6

4 Working of Flour Mill ............................................................................................................. 6

5 WASHING SECTION ............................................................................................................ 7

6 DISC CUTTER SECTION ...................................................................................................... 8

7 SIEVE SECTION .................................................................................................................... 9

8 BODY SECTION/BREAK SYSTEM................................................................................... 10

9 AIR LOCK SECTION........................................................................................................... 11

10 SHIFTER SECTION/PURIFICATION SYSTEM ............................................................ 13

11 WORM SECTION ............................................................................................................. 13

11.1 Working of Bran Machine.............................................................................................. 14

12 PACKER SECTION .......................................................................................................... 15

Table of figures

Figure 1 parts of the seed ................................................................................................................ 5

Figure 2 washing section ................................................................................................................ 8
Figure 3 Disc Cutter Units .............................................................................................................. 9
Figure 4 Sieving Units .................................................................................................................. 10
Figure 5 Break System .................................................................................................................. 11
Figure 6 Parts and Working of rotory airlock valve ..................................................................... 12
Figure 7 Air Lock Section in Flour Mill ....................................................................................... 12
Figure 8 Shifter Section ................................................................................................................ 13
Figure 9 Flour processing units .................................................................................................... 14
Figure 10 Packer section ............................................................................................................... 15

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1 Introduction
Rahim Yar Khan is an industrial district of Pakistan containing total 311 industries of small to
large scale. There are 62 flourmills in the district. Dehkan Flour Mills (Pvt) Ltd.is one of them. It
is a branch of Fahad General Mills. Dehkan Flour Mills was incorporated on 6 January 1994.

This industry produces different kind of wheat products, which include Flour, Maida, Semolina
and Bran. Daily processing capacity of the wheat is more than 70 US ton. There are multiple
storage tanks having total storing capacity of 132.27 US tons after washing the grains. Beside
these, there are two more storage tanks for temporary storage during processing. Overall 5
elevators (E) are working which carry the wheat against the gravity at upper sections of mill and
2 worm shafts that slide the grains to make available for carrying through elevators.

It was a half month On-Job Training (OJT) in which we explored different sections of the industry
including Washing Section, Air lock Section, Shifter Section, Disk Cutter Section, Worm Section,
Body Section, Sieving Section, Packer Section and then understood detailed working of each
section as described in later part of the report.

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2 Wheat Composition
Wheat grains, or kernels, are composed of the starchy endosperm, or food-storage portion,
constituting about 85 percent; several outer layers that make up the bran, constituting about 13
percent; and the oily germ, or embryo plant, approximately 2 percent. In the production of refined
flour, the purpose of the milling process is to separate the endosperm from the other kernel
portions. In the production of whole-wheat flour, all parts of the kernel are used.

Figure 1 parts of the seed

In modern milling of refined flours, the wheat kernels are cleaned and tempered by the addition or
removal of moisture and then split open by a pair of rolls. The finest particles, called break flour,
are sieved out and bagged. Coarser particles of endosperm (called semolina) and pieces of bran
with endosperm attached are then subjected to a series of rolls in which semolina of steadily
reducing size is gradually ground to flour and the bran separated out.

The wide variety of wheat flours generally available includes whole wheat, or graham, flour, made
from the entire wheat kernel and often unbleached; gluten flour, a starch-free, high protein, whole
wheat flour; all purpose flour, refined (separated from bran and germ), bleached or unbleached,
and suitable for any recipe not requiring a special flour; cake flour, refined and bleached, with very

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fine texture; self-rising flour, refined and bleached, with added leavening and salt; and enriched
flour, refined and bleached, with added nutrients

3 Treatment of Flour
The flour is usually bleached and treated to obtain the improved bread making qualities formerly
achieved by natural aging. Flour grades are based on the residual number of branny particles.

Use of “improvers,” or oxidizing substances, enhances the baking quality of flour, allowing
production of better and larger loaves. Relatively small amounts are required, generally a few parts
per million. Although such improvers and the bleaching agents used to rectify excessive
yellowness in flour are permitted in most countries, the processes are not universal. Improvers
include bromates, chlorine dioxide (in gaseous form), and azodicarbonamide. The most popular
bleacher used is benzoyl peroxide.

4 Working of Flour Mill

When wheat is received first at the mill, the first step to clean the grains from foreign material.
This is done with separators, sifters of varying sizes, air currents and scouring rollers among others
to remove dust, stones, leaves and other kind of materials that are mixed with the grains and are
stuck to the bran of the grain. It also passes through magnetic separators and high-speed rollers.

Next, the grain is moistened and washed. It is called tempering and it is done to ensure that the
'cover' or the bran from the grain is separated easily without damaging the inside or the endosperm,
which is the 'white' part from which flour is made. This is done in the tempering bin. It is then
passed on through separators again to remove damaged wheat kernels and the unwanted parts like
the germ and bran. The grains are now ready for grinding.

Now the purified grains are ground through corrugated rolls to come out as course particles of
flour. These particles are sifted through different sizes of sifters for a finer grain. Then they are
passed through purifiers and air currents to remove unwanted particles.

This process is repeated multiple times and size of the sifters keeps getting smaller to produce
whiter, finer and smoother flour.

(After every step, the flour that comes out is enriched with iron, calcium and vitamins. It may also
be bleached or processed further with chlorine gas if it is Cake Flour.)

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The particles, which do not get ground very fine and come as a by-product at each stage, are Shorts
or Middling or Grits. They are also called Farina or Semolina. (2) The first time flour is ground it
is called Straight Flour. It has high amount of bran, darker colour and more minerals and protein
the next time the process is repeated, it is called Patent flour. It has no bran, is whiter and finer and
is the best flour for breads. Once the process is repeated again with the remaining flour, it is called
Clear flour.

If the wheat is soft wheat, the grades that come after each step are Pastry, and all purpose flour. At
the last stage, cake flour is obtained. It is the finest and softest flour available.

For specific descriptions of flour by the companies, different grades are mixed. For example, high
gluten flour, iron enriched flour etc.

Sieving Sieve
Raw grains Storage Disk Cutter
Unit section

Sieve
Roll Peti Disk Cutter Storage Washing
Section

Body Shifter Worm Packing

Air Lock
Section Section Section Section

5 WASHING SECTION
Washing section at topmost floor consists of a sieving unit that initiates the processing of grains
by filtering it with non-wheat particles i.e. dust, stone etc. and a washing unit where grain is washed
before grinding. Sieving unit receives the grains from ground floor through an elevator (E1) and
sends this to a temporary storage tank having capacity of 20 US ton.

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 Figure 2 washing section

6 DISC CUTTER SECTION

This section that exist at 3rd floor has four (disc cutter) units, two of which process grains before
washing and two after washing. Each unit works by cutting the large dust and other particles into
smaller ones and processed grains lead into Sieve section through gravity. Two units i.e. D1 and
D2 receive unwashed grains from temporary storage tank through elevator (E2) and after
processing send to respective sieve units and other two collecting washed grains from large storage
tank through worm (W2) and then elevator (E4) and after processing sending to respective sieve
units.

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 Figure 3 Disc Cutter Units

7 SIEVE SECTION
Sieve section existing at second floor consisting of four sieve units namely S1, S2, S3 and S4.
These units comprises of meshes of different pore-sized, which separate the grains into precise
sized fractions and based on shape. Moreover, they perform the important function of filtering and
screening of light particles other than grains. Two units collect unwashed grains from Disk cutter
section and after filtering, send the grains into washing unit through elevator (E3) and wheat stalk
particles into bran machine of Mamni section through gravity. Other two units feed from respective
disk cutter units with washed grains and after screening, send the grains into Roll peti (a type of
storage) through elevator E5 and filtrate into a sieve unit of Mamni section.

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 Figure 4 Sieving Units

8 BODY SECTION/BREAK SYSTEM

Body section at first floor consists of 12 units and each unit called Break, so (B1-B12). The break
system is the beginning of the actual milling process. The object of the break system is:

• On the head breaks, to shear open the wheat berry and scrape the endosperm away from
the bran skin in as large sizes as possible and at the same time leaving the bran in as large
flat flakes as possible.
• On the lower breaks, to scrape off any adhering endosperm from the bran skins as cleanly
as possible,

This breaking open of the wheat and releasing of the endosperm from the bran gradually is a
mechanical process achieved by passing the wheat between fluted rolls, these flutes being cut in a
spiral, and the two rolls running at different speeds to produce a cutting or shearing action. The
amount of grinding decide by the degree to which the rolls are adjusted, and is measured by the
amount of endosperm released from the bran in this operation. The flutes also have a sharp edge
and a dull edge, the arrangement of these is known as the disposition of the flutes.

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 Figure 5 Break System

9 AIR LOCK SECTION

This section at topmost floor (4th) separates air from the product, which is discharged from a
cyclone separator into pneumatic system. It is installed under the cyclone separators and air filters.
It works with negative pressure as well as an air seal against leakage. From the air lock inlet, the
air-product mixture enters the chambers, which are created by fixing blades (wings) on the rotor
shaft. Due to the precise and standard tolerance between the body housing and the rotor, the
product is separated from air and discharged regularly without any leakage. Due to air leakage-
proof feature of the air lock, the escape of product is prevented together with air, which is sucked
by an existing collector. This section feed from body section through a lifter(L) and discharge to
Shifter section through gravity.

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 Figure 6 Parts and Working of rotory airlock valve

Figure 7 Air Lock Section in Flour Mill

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10 SHIFTER SECTION/PURIFICATION SYSTEM
This section is installed at third floor and consists of four units/machines called purifier. This
section feeds from Air lock section and after separating, the products send to their respective unit
in the Worm Section through gravity. Purifiers separate bran, pure endosperm and composite
particles in midsized coming from the sifting of the break system based on size, air resistance, and
specific weight. Bran are delivered to feed materials, and composite particles are sent to either
breaking system or sizing system based on the capacity, and the endosperm particles are also
classified and sent to the reduction rollers.

Figure 8 Shifter Section

11 WORM SECTION
Worm section have multiple units for different products i.e. Flour, Bran, Maida and Semolina.
Two bran machines receive the respected products from Shifter Section and process further before
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sending to packing section. Similarly, the units for flour and semolina process their own products
to convert into finished products.

11.1 Working of Bran Machine

Bran Machine uses a centrifugal action to gently separate the floury endosperm, attached to the
bran, thus reducing to the minimum the starch content of offal and ensuring high flour yield.

The product is thrown towards the screen by means of a wing - fitted rotor, which is rotated
horizontally; consequently, the flour and bran are separated from each other. Due to centrifugal
force, the product is thrown toward the screen whose size is selected beforehand. During the
screening process, flour passes through the screen and larger size of bran are directed to the
discharge outlet.

Figure 9 Flour processing units

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12 PACKER SECTION
Packer section consists of discharge units where Flour, Bran, Semolina and Maida are packed
manually and then stocked to introduce in the market. Based on quality different grades of every
product are made as follows

Flour: Fine (best quality of flour), Flour

Maida: Maida 1 and Maida 2

Bran: Bran Lighter, Bran Coarser

Semolina: Fine + Semolina(lower quality)

Figure 10 Packer section

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