| Cleaning | Foreign material removal | At least 98% removal of readily separable stones, stems, dust, and metal particles | Improve screening, aspiration, magnet inspection, and separator adjustment before dehulling | Incoming and cleaned-seed mass balance; periodic laboratory inspection |
| Moisture Conditioning | Seed moisture before dehulling | Generally 9–12% for soybeans; optimize separately for sunflower, rapeseed, and other oilseeds | Use controlled tempering to reduce hull adherence and prevent excessive kernel breakage | Moisture test at intake, after tempering, and immediately before dehulling |
| Dehulling | Hull removal efficiency | Approximately 85–95% hull removal, depending on seed type and final product specification | Balance rotor speed, clearance, feed rate, and seed moisture instead of maximizing mechanical intensity | Measure hull content in dehulled kernels and residual hull in the kernel stream |
| Dehulling | Kernel recovery | Keep whole and large kernel recovery above 90% where product specifications allow | Reduce over-conditioning, excessive rotor speed, and narrow clearances that create splits and fines | Screen dehulled material by size and calculate whole-kernel recovery by mass |
| Aspiration | Hull separation and air balance | Maintain stable air velocity and minimize kernel carryover in the hull stream | Install differential-pressure monitoring and adjust air volume as feed rate changes | Analyze hull-stream samples for kernel loss at least once per shift |
| Size Reduction | Particle-size distribution before flaking | At least 90% of particles within the selected preparation range; avoid excessive powder formation | Use a controlled crack-and-size-reduction step rather than excessive grinding | Use sieve analysis and track the percentage of fines below the process limit |
| Size Reduction | Fines generation | Keep fines below 5–8%, unless the downstream extraction process requires a different specification | Control roll gap, differential speed, screen condition, and feed uniformity | Sieve test at startup, after changeovers, and during throughput changes |
| Flaking | Flake thickness | Approximately 0.25–0.40 mm for many solvent-extraction preparations | Maintain consistent roll gap, roll parallelism, feed distribution, and seed temperature | Measure thickness at multiple points across the roll width using a calibrated gauge |
| Flaking | Flake integrity | Minimize powder and unflattened kernels; target a stable appearance across the full production run | Prevent uneven feed, worn rolls, excessive moisture variation, and unstable roll pressure | Visual inspection plus sieve analysis of fines and unflattened material |
| Energy Management | Specific energy consumption | Establish a site baseline in kWh per metric ton and reduce it by 5–10% without lowering product quality | Avoid over-processing, monitor motor load, and schedule roll and screen maintenance | Record electricity use and throughput continuously; compare by seed type and moisture |
| Process Stability | Throughput consistency | Keep hourly throughput within ±5% of the approved operating setpoint | Use automatic feed-rate control and alarm limits for moisture, motor load, pressure, and temperature | Review production data by hour and investigate deviations using statistical process control |
| Quality Control | Oil recovery potential | Improve extraction performance by maintaining uniform flakes and limiting fines, rather than relying only on higher mechanical intensity | Correlate flake thickness, residual oil, fines, and extraction yield in a daily process dashboard | Track residual oil in meal and oil yield against preparation quality results |
| Maintenance | Critical wear and alignment | Inspect rolls, screens, bearings, magnets, aspiration ducts, and sensors according to condition-based limits | Replace worn contact surfaces before they cause thickness variation, excess fines, or higher energy use | Use vibration, temperature, motor-load, and product-quality trends for preventive decisions |
Fabricator
Inside Sales and Client Support Manager
Glass Handler – 1st Shift