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Embarking on the journey of flour milling necessitates the crucial step of establishing a flour mill plant. Essentially, a flour mill plant is a collection of machines engineered to grind your flour into the preferred particle dimensions. The process of acquiring such a plant involves its meticulous design and construction by experts skilled in this specific field.

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Flour milling facilities have long been a cornerstone of agricultural processing. Like most agricultural industrial production facilities, flour milling facilities have many unique design requirements.

Flour milling is as old as human history. Ancient farmers used saddle stones or hand mills to grind grain into flour. In the Middle Ages, mills were invented that could grind large quantities of grain into flour. These first mills were powered by wind, water, animals, and even human power. Historically, each town had its own mill, where the miller would operate a portion of the finished flour. This was the centerpiece of each community and remained so for centuries. The advent of roller mills in the 1870s ushered in the development of the modern flour mill and the consolidation of the flour milling industry. Over time, consolidation has led to more technologically complex facilities. Today's flour mills integrate building facilities and process flows into a comprehensive, efficient, and highly automated structure. Due to this complexity, engineers must understand multiple technical areas in order to develop and operate a functional project.

This article aims to discuss the design and construction methods of modern flour mills. This article will discuss planning, life safety considerations, food compliance regulations, and building design and construction.

A general overview of the flour milling process.

The flour milling process begins with the receipt and storage of whole grains. The grain is stored in a bank of steel or concrete silos, which are laid out very similarly to a grain elevator. The grain then passes through a cleaning system located in a cleaning tower. The multi-story cleaning tower contains a variety of cleaning equipment, and the cleaning is done by machines that use airflow, magnets, and screens to separate the wheat from stones, sticks, other grains, and undesirable ingredients.

Equipment typically includes separators, de-stoners, magnets, vacuums, and other cleaning machinery.

After cleaning, the grain is moved to a temporary storage silo (called a clean store) before conditioning. Before milling, the wheat is moved to a conditioning silo at one end of the milling tower, where the moisture content of the clean wheat (or other grain) is adjusted to approximately 16%.

The milling process can then begin. The flour milling process includes a crushing system, a purification or grading system, a reduction system, and a tailings system. The milling tower is typically composed of 4 to 7 levels, with integrated silos at both ends of the tower. At one end is the conditioning silo, and at the other end is the finished flour silo. There are many levels between the silo groups, which house the various systems that complete the milling process. The tower is usually constructed of precast or slipform concrete.

Sometimes, smaller mills (part of a larger process) are built using only steel. The main elements of the milling process are as follows:The crushing system consists mainly of roller mills. In this system, the wheels in the roller mill run in opposite directions at different speeds and have a sawtooth structure. The purpose of the process is to separate the endosperm from the rest of the grain. For this purpose, the wheat passes through the roller mill up to five times. As part of the process, sieves are also used to separate the endosperm from the bran and germ, which are usually by-products known as wheat feed.The purification system consists of purifiers, roller mills, and sieves. The purifier classifies the particles based on size, air resistance, and specific gravity. The roller mill further reduces the size of the particles. Almost no flour is produced in this operation, and the material is either passed to the reduction system or sent back to the crushing system. The purpose of the purification process is to separate the small bran from the endosperm. However, the use of purifiers in modern mills is decreasing due to cost-effectiveness and the efficiency of other parts of the milling process. The reduction system consists of a series of roller mills and sieves arranged in sequence. The roller mills in this sequence are smooth and allow for a finer grind. At this point, the wheat is preferably subjected to mechanical starch destruction to improve flour quality. This stage reduces the endosperm to flour. This process is repeated up to 11 times to achieve the desired fineness of flour. The tailings system is where unwanted byproducts from the flour milling process go. These products are made into animal or pet food. These byproducts are usually sent out in bulk. Whole wheat flour has less tailings (or byproducts) and white flour has more tailings because more of the wheat kernel is used in whole wheat flour. In each system, the "excess" from each sieve (particles not fine enough to pass through the sieve) is directed to another set of rollers (i.e. back into the process) for further reduction, or to one of the tailings streams.

At the end of the process, the various flours are combined and blended to make the desired grade of flour. Malted barley, bleaching agents, concentrates, etc. are then added for processing before packaging or shipping in bulk. Large mills have complex processes to control the grade so that they can produce multiple grades of flour. Other smaller mills are often part of a vertical integration of a larger manufacturing process.

Finished bins are where finished flour is stored before it is packaged or shipped in bulk. Warehouses are where packaging takes place. Warehouses are usually made up of a single-story, large space with loading docks and palletizing equipment. These structures are usually constructed of steel and sheet metal or precast concrete. All buildings must be sanitary and easy to clean. Utilities keep the flour mill running, and air is a critical system for flour milling facilities. It is used to transport flour from one system to another and separate the streams into their components. It takes ten times as much air to move one unit volume of flour. The air system consists of fans, blowers, compressors, and pneumatic conveying lines. Other elements of the air system include cyclones, dust collectors, and filters.

B. Facility Planning Proper planning is an important aspect of the long-term profitability of flour milling facilities. It is important for engineers of these facilities to minimize these costs to increase value for owners and shareholders.

The main components of effective planning are to consider the following: (1) long-term planning, (2) food supply, (3) economic factors, (4) regulatory issues, (5) location/site, (6) facility expansion vs. new construction, (7) technology, and (8) facility layout. The best plan should reduce life cycle costs.

These are as follows:

• Long-term planning: Long-term planning or strategic planning is a function of the strategic vision and goals of the organization. It generally reflects the company's mission and how the company will achieve its business goals.

• Food supply: The main raw material for flour production is wheat. Wheat production depends on a strong local farming community or access to a railroad or road system. To produce flour, wheat must be brought in or grown locally.

• Economic factors: The economic considerations of a facility's operations can have a significant impact on its profitability and viability. Local issues such as the type and amount of food produced in a specific geographic location, the ease of transportation, and the number of existing facilities in a specific geographic area will directly affect the economic success of a flour milling facility. Global economic issues, such as long-term population growth and thus increased demand, can also be a consideration. Additionally, the dietary habits of the population or the processing capabilities of regional industries may affect production demand.

Return on investment (ROI) should be a major consideration in the decision to operate a new facility.

• Regulatory issues: Governmental and political issues can have a significant impact on the demand for a facility in a particular region. Issues such as Good Manufacturing Practices (GMP) and identity protection can have a significant impact on the international demand for a product.

• Location/site: Selecting an appropriate site is an important consideration in the profitability of a flour milling facility. A location close to suitable transportation and infrastructure is essential for facility operations. A fully functional rail facility is essential for most flour milling operations. Properly graded roads and highways are also essential for all operations with truck traffic. When looking for a new site, owners need to consider the bearing capacity of the soil. On an adequate site with good bearing capacity, the pressure beneath a grain storage facility may approach 6000 psf. The pressure beneath a mill may exceed 4000 psf. Other site issues may include drainage, wetlands, water, and other similar issues.

• Facility expansion vs. new construction: Once the decision is made to build a facility in a particular geographic area, the owner and engineer must first examine whether existing facilities in the area can be expanded or upgraded. If the discounted cash flow of the upgrade costs is greater than the cost of new construction, then construction of a new facility should be considered.

• Technology: Like all industries, the flour milling industry is an evolving industry, and technology is constantly changing. Senior managers and engineers must be aware of new technology trends being developed within the industry. As technology shifts, the company must be flexible and make changes when appropriate.

• Facility Layout: Facility layout and design are key considerations for functional facility operations. The relative location between the physical locations of receiving and loading, or the possibility of dual duty, can affect the cost of operating a facility. The type of building and the amount of land available have a significant impact on the physical layout of the facility. For example, a circular track for a 110-car rail shuttle loading system may require a large amount of land. Issues such as explosion or fire safety can also affect the physical layout of the facility.

The budget available to the facility owner can determine the type and size of building construction and equipment that can be undertaken, and can place severe restrictions on the design of the facility.

The layout of individual pieces of equipment can affect the total labor and power requirements of the facility.

C. Life Safety Design and Regulatory Design Considerations Once the owner and engineer have determined the layout, detailed facility design can begin

Apply life safety codes. They are implemented at the state, local, and federal levels. The Life Safety Code provides standards for the fireproof construction, occupancy, use, and egress design of industrial facilities.

Sections of the code address the design of stairways, work walking surfaces, and other detailed elements of a facility.

Flour milling facilities generate large amounts of explosive dust. Designers must take necessary steps during the design process to minimize the potential for deflagration.

The National Fire Protection Association (NFPA) has several documents that provide design standards for limiting the effects of dust explosions (NFPA, 2013a&b and NFPA 2014). Other regulatory considerations for food processing facilities, such as flour mills, include government regulations related to food production (NARA 2007). Many government agencies have specific requirements for sanitary construction of buildings and equipment. Imholt and Imholt (1999) is a good source for sanitary design methods.

During the design process, it is necessary for designers to comply with occupational regulations for workplace safety. These items can include work surfaces, fall protection systems, and general worker safety. Fire Protection Systems The use of active fire protection systems in industrial facilities, such as flour mills, can be used to increase the allowable floor area or height as described in various sections of the IBC. Type I buildings do not usually require an extensive area sprinkler system. Other times, a single-story building of unlimited area requires a fire sprinkler system. The need for fire sprinklers depends largely on the type of fireproof building. Personal insurance underwriters often have specific requirements for sprinklers. The design of fireproof systems is discussed in NFPA 13 (NFPA, 2013c) and the International Building Code (ICC, 2012 a & b).

D. Overview of Building Design Considerations Once the engineering team has determined the process layout, functional process areas, and functional building layout, the detailed design of the building systems can begin. Loads and Design of Major Components of a Flour Milling Facility.

Loads The loads on a flour mill come from a variety of sources, including wheat and its ingredients, flour, roof and floor live loads, equipment (including dynamic loads), dead loads, and lateral loads such as wind and seismic forces. Flour mills store large quantities of raw grain and finished flour in bulk and bagged form

Loads on the entire system must be determined before actual structural analysis and design can be performed. Items such as structural tower weight, equipment weight, snow, and floor and roof live loads must be determined. This information can be gleaned from equipment suppliers and building code documents such as ASCE 7-10 "Minimum Design Loads for Buildings and Other Structures" (ASCE, 2010).

Grain Storage, Retrieval, and Distribution Design Grain storage is a major component of a flour mill. Storage can be either concrete or steel structures. Typical concrete silos are 25 to 35 feet or larger in diameter and 100 to 120 feet in height. Corrugated steel bins can also be used to store grain. Corrugated steel bins are typically larger in diameter and shorter in height. Mixing and grading functions are desirable in bin layouts.

Grain silos should be designed to maintain a certain level of sanitation. For example, beams should be dusted, and attention should be paid to access sanitary and clean passages. In a flour mill, grain storage is typically divided into two sections: pre-clean silos and clean silos. Wall structures should be free of pits, dents, and other surface defects to prevent insect infestation. For concrete silos, this means that the interior of the silo should be trowel-finished. Steel silos should avoid having ledges.

Cleaning Towers Wheat cleaning towers are tall vertical structures used to house cleaning equipment. They are typically constructed of concrete or steel. Height is important because they utilize gravity flow between the various cleaning unit operations. Cleaning towers are typically rectangular in shape and consist of 4 to 6 stories. Due to their height, most cleaning towers are constructed using the slipform concrete method, although steel towers can be constructed using wood-frame steel systems. Conditioning Bins Conditioning bins are typically slightly smaller concrete or steel boxes used to store whole grain in cleaning bins and pre-cleaning bins.

The shape of these silos can vary depending on the size and shape of the structure that contains them. For example, if the tempering bins are contained within a slipform mill structure, they are cast integrally within the tower and are usually rectangular. If the silo is located within a steel mill, it is likely to be a circular steel structure and installed separately within the steel mill. In other cases, a slipform concrete silo may be considered. Finished Flour Silos Similar to the tempering silos, finished flour silos are smaller sanitary silos that are square or round in shape. Slipform silos tend to be square or rectangular, and steel silos are usually round. However, the shape can vary. These silos are used to hold finished flour, which is usually pneumatically conveyed into the silo. These silos can be either steel or concrete structures and must be high flow to work properly. Due to the final nature of the finished product, the construction of these silos must be sanitary. The surface must be smooth and free of pits, bumps and other surface defects. The welds must not only be structurally sound, but must also seal all joints and connections.

During the pneumatic discharge and filling process, the silos may develop internal pressure. Concrete silos must be designed in accordance with ACI 313-97 "Standard Specification for Design and Construction of Concrete Silos and Stacking Pipes for the Storage of Granular Materials" (ACI, 1997), and steel silos must be designed in accordance with API 620 "Recommended Practice for Design and Construction of Large Welded Low-Pressure Storage Tanks" (API, 2013).

Mill Construction - Construction Methods The mill portion of a flour mill is constructed using both concrete and steel structures. Typically, large mills are constructed using precast and slipformed concrete, or slipformed only. Slipform construction consists of cast-in-place concrete walls that are extruded continuously throughout the height of the structure.

Floor slabs can be constructed using both precast and steel beams. Precast beams can be set during the slipform process, with steel beams attached to inserts that are embedded during the slipform process. Floor slabs can be covered with precast or cast-in-place concrete that is set after the slipforms are completed. Sometimes, the mill processing floor is constructed using precast elements between the mill tempering and final product silos. In this case, the beams are attached to the slipformed wall inserts and supported by intermediate columns. Floor and roof elements are added to support the structure.

Precast beams can consist of inverted T-beams, spandrel beams, and rectangular beams, depending on the floor elements, which are usually hollow core slabs with bonded structural concrete on top.

All elements are supported by precast columns. Double T-beams are often used as structural elements for the roof, and the structure is surrounded by insulated precast wall panels, which can be double T-beams or flat-slab construction. The roof is then laid over the roof system. For design of precast elements, refer to the PCI Design Manual (2014). The frame of small or micro plants is usually built with steel structures.

Some of the smallest plants are skid mounted and integrated into larger configurations. Other plants use segmented or rod construction to form the structure. Typically, the structural steel structure consists of closed tubular columns and wide flange beams and steel joists. The walls are closed with insulated metal panels, although precast concrete can be used as the enclosure structure. When a steel joist ceiling is used, an insulated metal panel suspended ceiling is required. Sanitary structures must be followed and may include curbs, closed shapes, and shed beams. See the Sanitary Structures section for further comments.

Another design issue is floor vibration and the dynamic forces generated by the processing equipment. Vibration must be taken into account when designing the floor. As a first step, the operating natural frequency of the equipment should be compared with the natural frequency of the floor. There may be more than one natural frequency, so several modes must be investigated for each floor. Resonances may occur when the natural frequencies of the equipment and floor match.

Dynamic forces increase the loads on the supporting elements. Clough and Penzien (1975) provide an extensive discussion of vibration and dynamics. - Sliding Walls and Silo Construction Storage of tempered grain, flour, and by-products is accomplished using silos that are built integrally with the mill structure (Figure 4). Almost all mill towers are rectangular in shape. Concrete mill structures are fairly large and the walls are usually reinforced using vertical pilasters that extend the full height of the structure (Figure 6). Silos are built integrally with the mill shell and extend into the upper portion of the tower.

Packaging and Warehouse Construction After the wheat is ground into flour, it is stored in bulk and then shipped or packaged. In this section, we will describe the preferred construction methods for food grade warehouse construction. Food grade packaging and storage can be constructed with precast, tilt-up, or steel structures. Each facility has its own unique characteristics that will be discussed in the following paragraphs. When structural steel structures are used, the steel frame typically uses closed-shaped tubes as pillars for sanitary facilities. The primary beams are constructed of wide flange shapes, and the secondary roof frame is a rod-joist beam structure. The walls of these types of facilities are typically non-load-bearing precast and tilt-up, or alternatively, insulated metal panels. Standard metal building panels can be used, but insulated metal panels are preferred over standard metal building metal panels because they are cleaner.

For further sanitation, an American space or suspended ceiling should be added to enclose any mechanical ductwork within the facility. Precast warehouses typically consist of precast beams and columns and non-load-bearing precast wall panels. The columns and beam lines form the interior frame. Inverted T-beams or beams span across the columns, and precast double T-beams are used for roof structures. They are typically used to span from one beam to another. Flat T-shaped wall panels or double T-shaped wall panels are used to enclose the walls (Figure 7). Sometimes, the wall panels can be load-bearing. Add curbs where the bottom of the wall meets the floor. In addition, any beam shelves should be filled with mortar to form a slope to prevent the accumulation of dust and other materials.

Design procedures related to the construction, planning and operation of flour milling facilities. In particular, life safety, layout, planning and structural regulations are discussed. To this end, standards, procedures and methods for design and construction are discussed. I hope this will be helpful to your flour business. If you need further details, please contact us