Managing mill maintenance: Getting your dies and rolls re-worked locally to global standards

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Information about Managing mill maintenance: Getting your dies and rolls re-worked locally...

Published on February 18, 2014

Author: GFMT



O&J Denmark had the idea to re-work dies and rolls over three decades ago with an intention to assist the market demand to grind and re-countersink worn dies into ‘as-new’ dies at a time when dies were very expensive.

Digital Re-print January | February 2014 Managing mill maintenance: Getting your dies and rolls re-worked locally to global standards Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2014 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

MILL MAINTAINANCE Getting your dies and rolls re-worked locally to global standards by Leif Wolf, Director, O&J Hojtryk AS, Denmark O &J Denmark had the idea to re-work dies and rolls over three decades ago with an intention to assist the market demand to grind and re-countersink worn dies into ‘as-new’ dies at a time when dies were very expensive. installed properly with particular attention being paid to positioning of the roll assembly correctly against the die production surface. Failing to fit machines properly can result in non-uniform wear in the ring die and nonuniform pellets. The machines used for this work could not be bought at the time so we undertook the challenge to design, develope and manufacture such equipment ourselves. Since then many others and some from different perspectives have come up. However, O&J has been at the very forefront of this industry and still is. Clients of interest include: • Feedmills - for livestock such as pigs, poultry and cattle, shrimp feed • Bio/wood mills including palm fibre mills • Waste mills • Others The benefits from die- and rollrefurbishment include: • Increases life time of pelleting equipment • Increase throughput • Significant reduces power usage • Securing higher pellet quality A feedmill is only as strong as its weakest link. Each machine has to work as its best. Investing time and money in feed formulation can be quickly written off if the pelleting machinery used isn’t up to scratch. O&J Denmark has been able to establish a strong brand in the marketplace, servicing clients over very long distances. Thanks to great trust from all our clients we can offer a full re-working set up including logistic solutions. The mills book all shipments directly to our freight forwarding company operating in their region, bringing dies and rolls to our re-working center in Esbjerg, Denmark and returning with the same afterwards. Simple but highly effective – mills pay no waste time!, 1 click and the goods are booked and automatically returned again when the re-work is complete. In other regions throughout the g-lobe this may be different due to existing infrastructure, labour cost etc. At the re-working center dies and rolls are checked on arrival, their actual worn condition, any damage, etc, with assessment of how re-working would be or not be profitable to the client. It is a partnership. If a die is wrongly worn a contact shall follow from here giving a note to the client helping him back on track again. For example, a good client is a mill running controlled production systems and therefore will have a controlled degradation Installation and usage From the start, machines need to be Die- and roll-refurbishment of wear parts. It is worth remembering that a full refurbishment and cost will depend on the work required. Deciding when to ship a die for re-working is always a balance. Ultimately it comes down to a choice between controlled maintenance versus damaged based maintenance. A full refurbishment includes cleaning the die and checking for cracks by using the O&J HPJC21 High-Press Blowout System by means of water only – and without chemicals. The advantage of using this method is that the water is strong enough, blowing out with 1.250BAR/aprox 17,000PSI, to dislodge stubborn material without harming the press channels. Next, comes grinding the die production surface, skimming level and machining using the O&J DG1700-1 grinding machine specifically designed for dies and rolls. Finally, having it re-counter sunk again by using the O&J CSV14-3 counter sinking machine for ring dies. Differences between regions In the northern states of Europe and Scandinavia, mills generally carry out reworking to both ring dies and rolls. Ring dies get re-grounded, re-counter sunk and cleaned up - schematically dies get re-worked two or three times a lifetime, depending to production and die condition. Rolls are normally ground the first time and then given a new roll shell the next time. Also, items such as axles, bearings, cover plates and seal collars are cleaned up

35 | January - February 2014 and controlled before re-assembling which includes a new roll shell. In other regions throughout the globe, this may be different due to existing infrastructure, labour cost, etc. However, we register from those other regions an ever growing interest using our techniques and machines to set up service centers for re-working. We invest great interest in being at their service – working together facing a common future and possibility. A fine example is that a year ago we fulfilled delivery of technical equipment to the Philippines for a local service Grain centre in Cebu, which is now giving such re-working possibilities to local mills in that region. Even though there have been a few obstacles to overcome, the region shows great interest in the local set-up having their dies and rolls re-worked there and generally following the same ideas as we operate here. Apart from Europe, O&J machines are in operation in India, Thailand, Singapore, Korea, China, USA and Canada and there’s more to come – O&J is creating a future together with dedicated clients throughout the globe. More &Feed millinG technoloGy inforMation: O&J Højtryk A/S Tel: +45 75 14 22 55 Fax: +45 82 28 91 41 Email: Website: Empower your employees with tools and problem-solving skills at IAOM’s Fundamentals of Milling I and II courses, offered at Ocrim’s International School of Milling Technology in Cremona, Italy. Fundamentals of Milling I: March 17-21 Fundamentals of Milling II: March 24-28 Die and roll re-working machines Technical training courses that combine lectures and discussions with hands-on laboratory and pilot-scale milling exercises. Experience this unique learning environment where classroom, lab, manufacturing plant, and pilot mill all come together. International Association of Operative Millers 10100 W. 87th Street, Suite 306 Overland Park, KS 66212 USA T: +1 913-338-3377 | F: +1 913-338-3553 E: For more information, visit: Phone: +45 75 14 22 55 Fax: +45 82 28 91 41 mail: O&J Højtryk A/S Ørnevej 1, DK-6705 Esbjerg Ø CVR.: 73 66 86 11 M

LINKS January - February 2014 This digital Re-print is part of the January | February 2014 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on first published in 1891 • • Having no choice is not reasonable The quest for a healthier snack Design of an efficient intake pit dedusting system Silos special: Bulk storage challenges • Contact the GFMT Team • Subscribe to GFMT NIR: • Keep running costs down the state-of-the-art in technology • Visit the GFMT website In this issue: • • • See the full issue Production control in rapeseed processing using NIR technology operating en-masse chain conveyors • Getting your dies and rolls re-worked locally to global standards INCORPORATING PORTS, DISTRIBUTION AND FORMULATION A subscription magazine for the global flour & feed milling industries - first published in 1891 To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: or visit

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