PUNJAB-

FLOUR-MILL

SAFDARABAD DISTRICT SHEIKHUPURA

03414760967
[email protected]

ABSTRACT
Flour milling facilities have been the cornerstone of agricultural processing for centuries. Like most agri-industrial production
facilities, flour milling facilities have a number of unique design requirements.
Design information, to date, has been limited. In an effort to summarize state of the art design procedures for flour milling
facilities, an overview of accepted standards and procedures has been assembled and discussed. With this article engineers
should become more familiar with specific design considerations for flour milling production facilities and develop
appropriate references to expand their knowledge base. Educators may find this paper useful too.

INTRODUCTION
Flour milling is as old as human history. Ancient farmers used saddle stones or querns to grind their grain into flour. In the
middle ages, gristmills were developed that could grind larger amounts of grain into flour. These original mills were powered
by wind, water, animals or even humans. Historically, each town had their own mill, and the miller would operate for a portion
of the finished flour. This was the hub of each community, and remained that way for centuries. The development of the roller
mill in the 1870’s started the growth of the modern flour mill and the consolidation of the flour milling industry.
Over time, consolidation has resulted in more technically complex facilities. Today’s flour mill integrates the building facility
with the process into a comprehensive, efficient and highly automated structure. Because of this complexity, engineers must
have an understanding of multiple technical areas in order to develop and operate functional projects. The purpose of this
article is to discuss modern flour mill design and construction methods. This paper will discuss planning, life-safety
considerations, food compliance regulations, and building design and construction.

A. OVERVIEW OF A FLOUR MILLING FACILITY

The modern flour milling process was developed in the late 1800’s with the advent of the modern flour mill. Over the decades
improvements have been made to various aspects of the flour milling process, but the major elements of the process have
stayed essentially the same since the inception of the roller mill. Others have described the complete details of the flour milling
process (Owens 2000 and Posner & Hibbs 2004). Figure 1 shows the main building elements of a typical flour milling process,
and Figure 2 shows the layout for a typical flour mill. Figure 3 shows a section of a typical flour mill with some of its major
elements. The following paragraphs describe a general overview of the flour milling process.
The flour milling process starts with the receiving and storage of whole grain. Grain is stored in groups of steel or concrete
silos laid out very similar to grain elevators. The grain is then moved through the cleaning system which is housed in the
cleaning tower. A variety of cleaning equipment is housed in the multi-story cleaning tower, and cleaning is done with
machinery using air currents, magnets and screens to separate the wheat from stones, sticks, other grains and undesirable
elements. Equipment typically consists of separators, destoners, magnets, aspirators and other cleaning machinery. After
cleaning, the grain is moved to temporary storage silos (known as clean storage) prior to tempering.
Immediately prior to milling the wheat is moved to tempering bins at one end of the milling tower where the clean wheat (or
other grain) moisture content is adjusted to approximately 16%. The milling process is ready to begin. The flour milling
process consists of the break system, purification or sizing system, the reduction system, and the tailing system. The mill tower
usually consists of 4 to 7 levels with integral bins at each end of the tower. At one end are the tempering bins, and at the other
end are the finished flour bins. Between the bin clusters are many levels housing the various systems that complete the milling
process. The tower is usually constructed from precast or slip form concrete. Sometimes smaller mills (which are part of a
larger process) are constructed using only steel. The major elements of the milling process are discussed as follows:
The break system is primarily comprised of roller mills. In this system the wheels in the roller mills run in opposite directions
at different speeds and have a saw tooth configuration. The purpose of the process is to separate the endosperm form the rest
of the kernel. To achieve this, the wheat is run through the roller mills up to five times. As part of this process, sifters are also
used to separate the endosperm from the bran and germ which is typically a co-product known as wheat feed.

The purification system consists of purifiers, roller mills and sifters. Purifiers sort particles based on size, air resistance, and
specific gravity. The roller mills further reduce 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 break system. The purpose of the purification process is
to separate the small bran from the endosperm. The use of purifiers is decreasing in modern mills due to cost effectiveness and
efficiencies in other portions of the milling process, however.

The reduction system consists of a series of roller mills and sifters in sequence. The roller mills in this sequence are smooth,
resulting in a finer grind. At this point it is desirable to have mechanical starch damage to the wheat to improve flour quality.
This phase reduces the endosperm to flour. This process is repeated up to 11 times to obtain the fineness required for the
flour.

The tailings system is where the unwanted co-products of the flour milling process go. The products are turned into animal or
pet food. These co-products are often sent out in bulk. There are fewer tailings (or co-products) for whole grain flour, and
more for white flour, because more of the kernel is used for whole grain flours.

In each of these systems the “overs” of each sieve (particles not fine enough to pass through a screen) are directed to another
set of rolls (i.e. back through the process) for further reduction, or to one of the residue streams.

At the end of the process the various runs of flour are blended and mixed to make the required grades of flour. They are then
treated with the addition of malted barley, bleaching agents, enrichments, etc. before packaging or shipment in bulk.

Large mills have complex flows to control gradation to be able to produce multiple grades of flour. Other smaller mills are
usually part of a vertical integration of a larger manufacturing process.

The finished product bins are where the inished flour is stored prior to packaging or bulk shipment. The warehouse is where
the packaging takes place. Warehousing typically consists of single story, large square footage space, with loading docks and
palletizing equipment. These structures are generally constructed from steel and metal panels or from precast concrete. All
construction must be sanitary and easy to clean.

Utilities make the flour mill run, and air is a key system in a flour milling facility. It is used to convey flour from system to
system, and to separate streams into components. Ten times as much air is required to move a single volume of flour. The air
system consists of fans, blowers, compressors, and pneumatic conveying lines. Other elements of the air system consist of
cyclones, dust collectors, and filters.

B. FACILITY PLANNING
Proper planning is an important aspect of long-term profitability for a flour milling facility. It is important for engineers of
these facilities to minimize these costs to increase value for owners and shareholders. A major part of effective planning is
considering items such as
(1) Long Range Planning,
(2) Grain Supply,
(3) Economic Factors,
(4) Regulatory Issues,
(5) Location/Site,
(6) Facility Expansion versus New Construction,
(7) Technology, and
(8) Facility Layout. Optimal planning should lead to lower life cycle costs. These are detailed as follows:
• Long Range Planning: Long range or strategic planning is a function of the strategic vision and objectives of an organization.
It generally reflects the mission of the company and how it will proceed toward achieving its business objectives.
• Grain Supply: The primary ingredient in the production of flour is wheat. Wheat production is dependent on a strong local
farming community or access to a rail or highway system. To manufacture flour, wheat will have to be shipped in or grown
locally.

• Economic Factors: Economic considerations for the operation of a facility can have a major impact on its profitability and
viability. Local issues such as grain types and volumes produced in a particular geographic location, the availability of
transportation, and the number of existing facilities in a particular geographic area will directly affect the economic success of
a flour milling facility. Global economic issues, such as long-term increases in population, which in turn increase demand, can
also be a consideration. Additionally, the eating habits of the demographic population or the processing capabilities of regional
industries may have an influence on production demand. Finally, Return on Investment, or ROI, should be a major
consideration in the decision to operate a new facility.

• Regulatory Issues: Governmental and political issues can have a significant effect on the need for a facility in a particular
region. Issues such as Good Manufacturing Practices (GMP) and identity preservation can have a major effect on international
demand for products.

• Location/Site: Selection of an appropriate site is an important consideration for the profitability of a flour milling facility.
Locations close to applicable transportation and infrastructure are essential for facility operation. Functional rail facilities are
essential for most flour milling operations. Appropriately rated roads and highways are also essential for all operations with
truck traffic. When searching for a new site the owner needs to consider the bearing capacity of the soil. On a sufficient site
with good bearing capacity, pressures expected under the grain storage facilities can approach 6000 psf. Pressures under the
mill can exceed 4000 psf. Additional site issues can include drainage, wetlands, water and other similar items can come into
play.

• Facility Expansion vs. New Construction: Once a decision has to be made to build a facility in a specific geographic region, the
owner and engineer must examine if a currently existing facility in the area can be expanded or upgraded first. If the
discounted cash flow of the cost of the upgrades is greater than new construction then consideration should be given
construction of a new facility.

• Technology: Like all industries, the flour milling industry is an evolving industry with changing technology. Senior
management and engineers must be aware of new technological trends being developed within the industry. As technologies
shift, companies must be flexible and make changes when they are appropriate.

• Facility Layout: Facility layout and design is a key consideration in the operation of a functional facility. The relative location
between physical locations of the receiving and load out, or the possibility for double duty, can play a role in the operational
costs of running the facility. The type of construction and the amount of available land can have major role in the physical
layout of the facility. For example, a loop track for an 110-car rail shuttle loading system can require a vast amount of land.
Issues such as explosion or fire safety can influence the physical layout of a facility as well. Finally, the budget that the facility
owner has available can dictate the types and sizes of building construction and equipment that can be pursued, and can place
severe restraints on the design of the facility. Additionally, the layout of individual pieces of equipment can have an effect on
the total labor and power requirements of the facility.

C. LIFE SAFETY DESIGN AND REGULATORY DESIGN CONSIDERATIONS

Once the layout has been determined by the owner and engineers, the facility detail design can begin. One of the first steps is
application of the life safety codes. They are administered at state, local, and federal levels. Life Safety codes provide standards
for the design of fire rated construction, occupancy, use, and egress of a plant facility. Additionally, there are code sections for
the design of elements such stairs, working walking surfaces, and other detail elements of a facility. Flour milling facilities
produce extensive amounts of explosive dusts. The designer must take the necessary steps during design to minimize the
potential for deflagration. The National Fire Protection Association produces several documents that provide design criteria
for limiting the effects of dust explosions (NFPA, 2013a&b, and NFPA 2014)
Other regulatory considerations for food processing facilities such as a flour mill include government regulations (NARA 2007)
related to the production of food. Many governmental agencies have specific requirements for sanitary construction of
buildings and equipment. A good source of design methods for sanitary design is Imholt and Imholt (1999). Additionally,
during the design process it is necessary for the designer to occupational regulations for workplace safety. These items can
include working surfaces, fall protection systems, and general worker safety.
Fire Protection Systems
The use of active fire protection systems in industrial facilities such as flour milling facilities can be used to increase allowable
floor area or height as described in the various sections of the IBC. Type I construction typically does not require sprinklers for
large areas. Other times, fire sprinkler systems are required for unlimited area single story buildings.. The need for fire
sprinklers is highly dependent on the type of fire rated construction. Individual insurance underwriters often have particular
requirements for sprinklers. Design of fire protection systems is discussed in NFPA 13 (NFPA, 2013c) and the International
Building Code (ICC, 2012 a & b).

D. BUILDING DESIGN CONSIDERATIONS

Overview
Once the engineering team has determined the process layout, the functional process areas, and the functional building layout,
the building system detailing can begin. In this section descriptions of the loads for and design of the major elements of flour
milling facilities will be discussed. As part of this discussion, major design standards will be referenced and key aspects will be
highlighted. This is not intended to be an all-inclusive discussion of all elements involved in the design process, but rather to
highlight unique or significant aspects of the design process for flour milling facilities.

Loads
Loads on flour milling facilities arise from a variety of sources, including wheat and its components, flour, roof and floor live
loads, equipment (including dynamic loads), dead loads, and lateral loads such as wind and seismic forces. Flour milling
facilities store large quantities of raw grain and finished flour products in both bulk and bag form. Material handling
characteristics and flow properties for common ingredients in the flour milling process are provided in Table 1. Before an
actual structural analysis and design is undertaken, the loads on the total system must be determined. Items such as structural
tower weights, equipment weights, snow, and floor and roof live loads must be determined. This information can be gleaned
from equipment vendors and from the building code documents such as ASCE 7-10 “Minimum Design Loads for Buildings and
Other Structures” (ASCE, 2010).

Grain Storage, Reclaim and Distribution Design

Whole grain storage is a major component of a flour milling facility. Storage may be of either concrete or steel construction.
Typical concrete silo diameters vary between 25 to 35 feet or more with heights between 100 to 120 feet. Corrugated steel
bins can also be used as whole grain storage. Corrugated steel bins typically will be larger in diameter and squatter. Blending
and grading capabilities are desirable in a bin layout. Whole grain silos should be designed so that that some level of sanitation
can be maintained. For example, beams should be dust shedded and attention should be paid to access for sanitation and clean
out. In a flour milling facility, grain storage is often broken into two components: pre-clean and clean silos. Wall construction
should be free of pits, pockets and other finish defects to inhibit insect infestation. For concrete silos this means that the inside
of the bin should be trowel finished. Steel silos should avoid ledges.

Cleaning Tower
Wheat cleaning towers are tall vertical structures that house cleaning equipment. They are usually constructed from concrete
or steel. Height is important because they take advantage of gravity flow between the various cleaning unit operations.
Cleaning towers are usually rectangular in shape and consist of 4 to 6 levels. Due to their height, most cleaning towers are
constructed using slip form concrete methods, although it is possible to build a steel tower utilizing stick-built steel systems.

Tempering Bins
Tempering bins are usually somewhat smaller concrete or steel bins that are used for storing whole grains in the clean and
pre-clean 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 inside a slip formed mill structure, they are integrally cast in the tower and are
typically rectangular in shape. If the bins are contained inside a steel mill, then it is likely that they will be of round steel
construction and separately installed in the mill. In other scenarios, slip formed concrete silos could be considered.

Finished Flour Bins

Similar to the tempering bins, the finished flour bins are smaller sanitary bins of either square or round shape (figure 4). Slip
formed bins tend to be square or rectangular and steel bins are typically round. Shapes can vary however. These bins hold the
finished flour, which is typically pneumatically conveyed into the bin. These bins can be either steel or concrete construction,
and must be mass flow in order to properly function. Because of the final nature of the finished product, these bins must be
sanitary in construction. Finishes must be smooth, free of pits, ledges and other surface defects. Welds must not only be
structurally strong, but must also seal all joints and connections. With pneumatic discharge and filling it is possible that the bin
could develop internal pressures. Concrete bins must be designed according to ACI 313-97 “Standard Practice for the Design
and Construction of Concrete Silos and Stacking Tubes for Storing Granular Materials” (ACI, 1997) and steel bins must be
designed according to API 620 “Recommended Rules for the Design and Construction of Large, Welded, Low-Pressure, Storage
Tanks.” (API, 2013).

Mill Construction
– Construction Methods
Both concrete and steel construction are used for the construction of the mill portion of a flour milling facility. Typically, large
mills are constructed using precast and slip form concrete, or just slip form alone. Slip form construction consists of cast in
place concrete walls that are extruded continuously over the entire height of the structure. Floors can be constructed using
both precast and steel beams. Precast beams can be set during the slip form and steel beams are attached to inserts that are
embedded during the slip form (figure 5). Floors can be topped precast or cast in place concrete which is set after the slip form
is complete.
At times the mill processing floors are constructed between the mill tempering and final product bins using precast elements.
When this occurs, beams are attached to slip wall inserts and supported by intermediate columns. Floor and roof elements are
added to support the structure. Precast beams can consist of inverted tee, spandrel, and rectangular beams depending on the
floor elements, which are usually hollow core plank with a bonded structural concrete topping.

All the elements are held up by precast columns. Double tees are usually used as structural elements for the roof, and the
structure is enclosed by insulated precast wall panels which can be either a double tee or flat plate style construction. Built up
roofing is then applied over the roof system. For design of precast elements the reader is referred to the PCI Design Handbook
(2014).

Smaller, or mini mill, frameworks are usually built using steel construction. Some of the smallest mills are skid-mounted and
incorporated into a larger configuration. Other mills are constructed using piecemeal or stick-type construction to form the
structure. Typically, a structural steel configuration consists of closed tube columns and wide flange beams with bar joists. The
walls are enclosed with insulated metal panels, although precast concrete can be used as the enclosure. When a bar joist
ceiling is used, an insulated metal panel drop ceiling needs to be installed. Sanitary construction must be followed and could
include curbs, enclosed shapes, and shedded beams. See the section on sanitary construction for further commentary.

Another design concern is floor vibrations and dynamic forces from the processing equipment. Care must be taken during the
design of the floors for vibration. As a first step, the operating natural frequency of the equipment should be compared to the
natural frequency of the floor. More than one natural frequency is possible, and so several modes will have to be investigated
for each floor. When the natural frequency of the equipment and the floor match it is possible to have resonance. Dynamic
forces will increase loading on supporting elements. An extensive discussion of vibrations and dynamics occurs in Clough and
Penzien (1975).

– Slip Wall and Bin Construction

Storage of tempered grains, flour, and co-products are accomplished using bins built integral to the mill structure (figure 4).
Almost all mill towers are rectangular. Concrete mill structures are fairly large and the walls typically need stiffening using
vertical wall pilasters (figure 6) that extend the entire height of the structure. Bins are constructed integrally with the outer
mill shell, and extend about the upper portion of the tower.
Packaging and Warehouse Construction
Once the wheat is milled and turned into flour it is stored in bulk and either shipped or packaged. In this section we will look at
preferred construction methods for food grade warehouse construction. Food grade packaging and storage warehousing can
be constructed from precast, tilt-up, or steel construction. Each has particular features that are discussed in the following
paragraphs.
When structural steel construction is used, steel frames are often constructed using closed shaped tubes as columns for
sanitation. Primary beams are constructed from wide flange shapes and the secondary roof framing is of bar joist construction.
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 could be used, but insulated metal panels are preferred over standard metal building metal
panels because of their greater cleanliness. For further sanitation, a USA space or suspended ceiling should be added to
enclose any mechanical piping in the facility.
A precast warehouse usually consists of precast beams and columns with nonload bearing precast wall panels. Column and
beam lines form the interior frame work.
Inverted tee or ledger beams run over the columns and precast double tees are used for the roof construction. They typically
are used to span from beam to beam. Flat or double tee wall panels are used to enclose the wall (figure 7). Occasionally, wall
panels can be load bearing. Curbing is added at the base of the wall where it attaches to the floor slab. Additionally, any ledger
beam shelved should be filled with grout to form a slope to prevent dust and other materials from accumulating.

PRODUCT & SERVICES:

Problem of the society you are trying to address through your startup/business idea. What are
you offering to the customers/community and how is it different from other solutions available in
the market? 

For the startup of business of idea I am facing financial trouble and due to this I can’t start business. I’ll provide to customers
flour mill products (

1-Fine Flour (Plain Aata) -We offer Fine Flour which is hygienically prepared under the proper leadership of trained
professionals having abundant experience in dealing with all sorts of whole grain wheat flour. We have carved a niche for
ourselves in the heart of our esteemed clients via our superlative products. Our esteemed clients will be amazed to know that
we offer whole grain wheat flour at the most competitive price.

2-Pure Fine -All kind of Pure Fine White Flour can be easily obtained at Premier Flour Mills – quality-oriented business house.
We offer Pure Fine flour having high proportion of starch – a complex form of carbohydrates. We also manufacture Pure Fine
white flour as per clients need and requirements. We are one of the paramount Pure Fine wheat flour exporters, originated in
Pakistan. We strictly use up-to-date equipment’s in the entire manufacturing process ensuring optimum quality production.
Clients’ satisfaction is our high priority.

3-Baking Flour (Maida) -We manufacture baking flour (Maida) which is 100% free from the presence of any harmful
ingredients. Our baking flour (Maida) contains high level of nutritional level for the regular growth of body. For making soft as
well as nutritious Chapatti, we manufacture baking flour (Maida). We have a team of trained professionals having abundant
experience in dealing with baking flour (Maida) .

Moisture 13 % -13.5 %

Total Ash 0.5 - 0.55 %

Acid Insoluble Ash 0.015-0.02

Alcoholic Acidity0.02%-0.03%

Gluten 28% - 30 %

Water Absorption Power Min.60%

Sedimentation Value 23ml - 24ml

Maltose Value 2.5mg - 3.5mg

Protein Crude 12 % - 13 %

Crude Fiber Max. 2.5% - 3%

Starch 73% - 75%

Colour Creamish White

It is used for preparing in various items some of them are Bread, Burger Buns, Rusk, Pasta, Noodles, Pizza Dough,
Cake/Pastries, and Biscuits etc. Click here to view full details.

4-Bran (Choker) -Bran is the outer coat of wheat also named as "Choker". Premier Flour Mills is a customer-oriented business
house from where you can obtain wide assortments of Wheat Bran Fiber. We strictly accentuate on the top quality raw
material in the entire manufacturing process which is sourced from noted suppliers across the world. Our dietary wheat bran
fiber is universally praised for its superior quality. We are one of the well-known wheat bran fiber manufacturers, incepted in
Pakistan. We offer dietary wheat bran fiber at the most affordable price.

Fiber Crude 2.5%

Protein 15% - 16%

Moisture 13% - 14%

Wheat Bran is the best food for cattle’s and helps in increasing the milk production and keeps them healthy. It is rich source of
protein etc.)

And also provide services (

Weighbridge -Weighbridge is also concern of Flour Mills, to control our totally output and input by weighing scale having
capacity 5 Kg’s to 50 Tons, company all raw material such as wheat products such as Maida, Atta and Bran weighted before
leave the zone, all weighing slip are kept for record for our customers satisfaction.

This weighbridge also facilitate to the other consumer commercially and large numbers of other industries situated
surrounding of this area are trust on our weighment quality and standard, this setup is always a first recommendation of all
Industries of Korangi Industrial Area.

- Two numbers of steel longitudinal girder.

- Carrying strength about 1.5% more than rated capacity.

- Distributed load over the over bridge length.

- Standard length of load cell integral cable 20 meters.

Environmental conditioning.)

I’ll also provide home delivery service to regular and local customers.

By providing these type of services to customers, it is different from other solutions available in the market.

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