ALFIL MILLERS LIMITED

AUGUST 2019
MONTHLY OPERATIONS &
MAINTENANCE REPORT
 Monthly Report of Operations and Maintenance
For Alfil millers for both mill A and B and motor vehicles For
the Month of august 2019

SEPTEMBER 7TH, 2019

GENERAL MANAGER

ALFIL MILLERS LTD

Dear Sir:

The maintenance team is pleased to present the attached Monthly report. Included is a detailed
report of operation and maintenance of both Mill A, Mill B and motor vehicle for the month of
August. The maintenance team welcomes any comments or questions on this report.

Sincerely,

Maintenance team
Executive Summary
The Month of August has been a full month but productive. The month ran very well until the
end of August. During this month, we only experienced one break down on the scouring
machine and majority of the work for the month of August has been daily and weekly
preventive Maintenance in both mills. The maintenance team has managed to install dead
boxes at various points inside mill B as it was planned during July. We have also fabricated and
installed one permanent by-pass pipe between the scouring machine and radial aspirator for
second cleaning stage after it broke down the second time. The sole purpose for this is to
reduce production down time and grain loss during future break down repairs. We have also
continued with the pending work of greasing from July and all Rollers inside mill B are now
finished. The remaining part is only Plan-Sifters and Mono-Case which will be greased at the
beginning of September. We have also experienced difficulties in removing cobwebs especially
mill B because of safety issues, and we hope the company can provide a scaffold for
effectiveness of the work.

The maintenance team and other departments also attended a training workshop with UNBS
staff regarding quality and food safety management systems during the month of August. The
workshop was effective and beneficial to us and we like to thank the company and
management for that tremendous opportunity.
Corrective maintenance at mill B

During the month of July, the following were noticed during daily inspection;

1. The rapid wear and tear of stainless steel magnetic housings, cast elbows and grain
pipes that are deteriorating so fast due to high speed and friction of wheat grain during
processing.
2. During production, elevator cups accidently break off from some belts and find their
way to the bottom of the grain silos, in here, some block the volumetric measurers and
since they are connected to electric motors, the motor gets overloaded and burns down
like in previous case at mill B. Other cups get stack and make flow of grain from silos
totally difficult hence interrupting production.

The maintenance team decided to fabricate dead boxes to install at various critical points inside
mill B. dead boxes were fabricated in July and installation has been done in this month of
(August) as shown below to reduce the rate of wear and tear of grain pipes and stainless steel
magnetic housings and cast elbows. All this is done to prolong the lifespan of company
equipment for maximum value.

1. At separator line

Two dead boxes have been installed at separator line between bucket elevator and separator
to reduce the speed of the grain and consequently reduce the rate of wear and tear on
magnetic casing, grain pipes and cast elbows on this line.

Damaged area due to grain friction as a

result of high speed moving grain
Dead box installed on top of
magnetic housing to reduce
the speed of moving grain.
(Before painting)
 Second dead box installed on the
same line before painting

2. Another dead box was installed at the by-pass pipe on second cleaning between radial aspirator
and scouring machine.

Dead box installed on by-pass

pipe (before painting)

3. The last dead box was installed at elevator head; this was purposely to prevent broken metallic
elevator cups from entering the grain silos.
 Dead box at elevator head
(before painting)

4. During last month (August) we also fabricated and installed one permanent by-pass pipe
connecting elevator bucket to both scouring machine and radial aspirator for second cleaning as
illustrated below. This would prevent down time

By- pass pipe between radial

aspirator and scourer before
painting

Installed dead box

 By-pass pipe with two inlet valves
(after painting with 9003 white 2
pack acrylic finish)

Note, installation of dead boxes will continue to take place at various points in mill B where necessary to
serve the same purpose. For instance on some cast elbow joints, magnetic housings and other places
where deem necessary.

Second damaged magnetic housing

on top of apex separator after
applying silicon
Preventive maintenance at both mills

As far as maintenance regards, we carry out daily, weekly and monthly prevent maintenance on
both mills and other small changes where necessary to smoothen production. During last
month (August), the following were carried out;

Completing the greasing of all rollers in mill B and what is left are two Plan-sifters and one
mono-case which will be completed in the next month (September)

1. Daily maintenance includes blowing of both mills, draining of condensed vapor from both
compressors and daily inspection of mill equipments during production to identify and
rectify any fault before it intensifies.
2. Weekly maintenance done in August includes;
 Cleaning of magnets in both mills
 Cleaning of air filters on blowers
 Cleaning dampening machine to remove rotten grain
 Blowing of low pressure fans inside mill B to avoid excessive vibrations that may
damage electric motor bearings
3. Other maintenance work done last month includes;
 Emptying choked cyclone and pipes
 Maintenance of sawing machine at mill A which had failed to work
 Installing of inspection inlets on floor pipe for smooth removal of choked floor
without damaging pipes as shown below;

Inspection gate at floor

pipe
 Installing wall protection in front of bran loading bay at mill B to prevent trucks
from further knocking of the wall as this had become frequent.

Cracks at the wall

Wall protection
Workshop training with UNBS staff

We had workshop training on food safety and management system with UNBS staff last
month. During the training, we learnt about food safety and contamination, food
fortification and its core values and food safety management systems and Documentation.
The workshop was thoroughly beneficial and highly educative. We thank the company
management for this beautiful opportunity.

Operations high light on motor vehicle maintenance

 Servicing air drier for Fuso Super great UAW 138Y

 Servicing brake calipers, replacing faulty brake disk on UBD 358G
 Servicing brake fluid line for General Manager’s vehicle

PERSONNEL

The maintenance team includes one motor vehicle & one maintenance mechanic, one welder
and two technical helpers. The team work hand in hand to deliver precise results. The team also
works hand in hand with productions team to ensure proper mill maintenance.
APPENDIX

New brake disc installed on

UBD 358G

Serviced brake caliper on

UBD 358G
Dead box after painting
with 9003 2 pack acrylic
white refinish

Dead box on top of refuse

separator after painting
with 9003 2 pack acrylic
white refinish
Dead box between refuse
separator and bucket elevator
after painting with 9003 2 pack
acrylic white refinish