Systèmes d'automatisation des usines Un

1. Introduction

• The role of automation in flour production process
• Increasing production efficiency, reducing error rates, and standardizing quality
• The necessity of automation in modern flour factories

 2. Level Sensors and Applications

In flour factories, level sensors are used to determine the fill levels of the raw material and product storage areas.

 Applications:

• Wheat silos: Raw material stock management
• Pre-milling bunkers: Regulation of feeding process
• Flour storage silos: Product stock management and capacity control
• By-product storages: Monitoring the levels of bran and other by-products

Used Level Sensors:

• Ultrasonic sensors - Makes contactless measurements, ensures high accuracy
• Radar sensors - Can provide accurate measurements even in dusty environments
• Capacitive sensors - Detects the levels of solid and liquid materials
• Mechanical float sensors - Traditional but robust method

Advantages:
✅ Optimizes raw material stock control
✅ Prevents overflow and underfeeding risks
✅ Determines the required amount of raw material for continuous production

3. Yield Scales

Yield indicates the amount of flour obtained from a certain amount of wheat. Yield scales are used in flour factories to monitor production efficiency.

 Working Principle:

• The difference between input and output scales is calculated to determine yield
• Constantly monitored with PLC and SCADA to optimize production processes
• Data is provided to operators for detecting production errors

 Advantages:
✅ Increases production efficiency in flour production
✅ Reduces waste of raw materials, thus reducing costs
✅ Provides continuous data to maintain production quality

4. Flow Scales

Flow scales perform weight measurements in production lines where raw materials and products move continuously.

Applications:

• Control of wheat flow before grinding
• Precise dosing of mixtures and additives
• Determination of quantities of by-products (bran, millfeed, etc.)

Advantages:
✅ Ensures precise control of the production process
✅ Prevents dosage errors by instant weighing
✅ Maintains continuous flow in the production line

5. Packaging Scales

At the packaging stage, it is crucial to bag the right amount of flour and prepare it for shipment.

Working Principle:

• Flour arrives at the weighing bunker and is filled into bags in the specified amounts
• Filling and conveying operations are carried out by belt systems
• The automation system detects erroneous weighings and makes necessary adjustments

Advantages:
✅ Increases weight precision
✅ Enhances production capacity by quick and accurate filling
✅ Reduces human errors and loss rates

6. Process Operation Systems

In flour production, process automation ensures smooth and synchronized operation of all production stages.

 Processes Controlled by Automation:
1️.Cleaning and moisturizing of wheat
2️.Automatic control of milling machines
3️.Quality control with sieve systems
4️.Dosing of mixtures and additives
5️.Monitoring packaging and shipment processes

Advantages:
✅ Ensures integrated management of all processes
✅ Early detection of production errors
✅ Provides remote monitoring and control options with SCADA systems

 7. Future Technologies and Smart Factories

With advancing technology, automation in flour factories is being taken to a more advanced level.

 Next-Generation Technologies:
 IoT (Internet of Things): Interconnected operation of all machines and sensors
 AI-Supported Systems: Automatic error analysis and production optimization
 Big Data Analytics: Processing production data for optimal efficiency
 Remote Monitoring and Control: Production tracking with mobile applications and cloud-based systems

8. Conclusion and General Evaluation

✅ Automation systems in flour factories make production processes more efficient, safe, and cost-effective.
✅ Level sensors, yield scales, flow scales, and packaging scales play critical roles in every stage of production.
✅ Process automations integrated with SCADA and PLC systems enable factories to become fully automated.
✅ New generation technologies such as IoT, AI, and big data analytics aim for maximum efficiency in production.