Equipment for processing buckwheat. Integrated technology for processing buckwheat with utilization of husks Homemade machines for producing buckwheat cereals
Buckwheat is one of the main types of grain for cereal factories.
From it they produce:
- buckwheat groats - whole, unchopped buckwheat kernels, freed from fruit shells;
- prodel - core particles freed from shells, split during processing;
- Smolensk groats - crushed groats - kernels, produced by special order.
- brown cereal - produced under special orders. It is a core that has undergone additional hydrothermal treatment;
- dietary buckwheat flour is a by-product in the production of Smolensk groats. It is also specially produced from the kernel.
The process of processing buckwheat into cereal consists of the following sequential technological operations:
- cleaning grain from impurities by passing it twice through separators, through triremes (in cases where buckwheat is contaminated with wild oats or contains grains of wheat and rye) and through destoning machines;
- hydrothermal treatment of purified grain by steaming it in special steamers, drying to bring the humidity to 13.5% and cooling;
- preliminary sorting on BKG grain sorting machines into two streams (large and small grain);
- final sorting into six fractions followed by independent processing of each fraction separately. Sieves for final sorting of buckwheat into fractions should have the following dimensions.
Buckwheat is shelled on double-deck 2DSHS-ZB or single-deck SVU-2 hulling machines.
The operating mode of the hulling machines is set so that after passing through the buckwheat, the number of hulled grains is no less than indicated previously.
An intermediate selection of the kernel with sifting of peeling products should be organized. This operation is carried out on BKG grain sorting machines.
Hulled grains, after additional passage through sorting machines, where flour is separated and processed, are sent (after control) to. ready-made cereal. The mixture of unhulled grains and husks is winnowed to separate the husks and sent for re-hulling.
The produced cereal must meet the following quality standards: the content of a good quality kernel in the first grade kernel must be at least 99.2%, in the second grade 98.3% and in the whole kernel 98.3%, including broken grains in the first grade there must be no more than 3.0% and in the second - 4.0%. The amount of unhulled grains in the first grade is no more than 0.3%, in the second grade 0.4% and in the second grade 0.1%.
The yield and waste standards for processing buckwheat of basic conditions are given in Table 41.
In addition to buckwheat, dietary buckwheat flour is produced from the kernels. To do this, the kernel is additionally cleaned using grain cleaning machines, washed in warm water (at a temperature of 35-40°C), followed by drying to 10%, and crushed by passing it twice through roller machines. The coarseness of dietary flour is characterized by a residue on silk sieve No. 27 of no more than 2% and passage through silk sieve No. 38 of no less than 60%.
In 1968 - 1975 VNIEKIprodmash proposed and implemented with the participation of Mirgorod MIS new way(technology) for the production of buckwheat.
A new method for producing buckwheat involves cleaning and peeling grain that is not sorted into fractions by size. Hulled grains are separated from unhulled grains on mesh sorting tables after preliminary removal of shells, flour and crushing.
To improve the quality and grade of cereals, as well as increase its yield, unsorted grains are successively shelled four times on rubberized rollers. After peeling, the subsequent machines are fed with the upper waste obtained after sorting the grain, and the grain is removed sequentially in several stages, sorting the enriched mixture on grain separating machines. In this case, the upper runoff obtained after sorting is sent for control, and the lower runoff from the last stage of grain separation is sent to the first sorting zone. The multiplicity of peeling and, accordingly, the number of stages of grain separation are equal to four.
This method of producing buckwheat can significantly reduce the internal turnover of the product, increase the productivity and efficiency of the technological process for producing grain.
The drawing shows a diagram for implementing the method (Fig. 1). The processed grain (buckwheat) enters the 1st peeling system 1U, which includes machines with rubber-coated rollers of the ZRD type. From the 1st system, peeling products are sent to sieving 2.
From sieves with holes diameter 4 mm, sieving 2, after winnowing on an aspirator 3, the product is sent to a sorting machine 4 with reciprocating motion of the sieves to separate foreign impurities and additionally separate the hulled grain.
Rice. 1. New technological scheme for the production of buckwheat:
1, 5, 13, 19 - 1-, 2-, 3-, 4th peeling systems, respectively; 2, 10, 16, 21 - sieves; 3, 11, 17 - aspirators with a closed air cycle; 4, 12, 18 - sorting machines; b, 7, 8, 14, 15, 20, 22 - coarse separating machines
From sieves with holes Ø 4 mm of sorting machine 4, the product enters the 2nd peeling system 5. The output from sieves with holes measuring 1.7 x 20 mm of sieving 2 and sorting machine 4, enriched with peeling products (kernel content 90...95 %), obtained after a sieve with holes diameter 4 mm, is sent to grain separating machines 6 with cellular tables (I stage of kernel separation), oscillating with a frequency of no more than 3.3 s-1 (200 rpm). The separated kernel is sent to the control grain separating machines 7, and the product obtained from the lower exit from the grain separating machines 6 is sent to the grain separating machines 8 (II stage of kernel separation). The product from the upper discharge of grain separating machines 6 and 8 goes for additional control to the sorting machine 9, from where the discharge from a sieve with holes measuring 1.7 x 20 mm goes to the control grain separating machines 7. After the 2nd peeling system 5, the products are sent to sieving 10. The output from a sieve with holes 0 4 mm of sieving 10, after winnowing on an aspirator 11 and sifting on a sorting machine 12, goes to the 3rd peeling system 13. The product coming off sieves with holes measuring 1.7 x 20 mm of sieving 10 is sent to grain separating machines 14. After grain separation, the product from the upper collection (kernel) goes to the control systems of grain separating machines 7, and the lower discharges - to grain separating machines 15. After the 3rd peeling system 13, the products are sent to sieving 16. Discharge from a sieve with 4 mm sieving holes 16, after winnowing on an aspirator with a closed air cycle 17 and sifting on a sorting machine 18, is supplied to the 4th peeling system 19. The discharge from a sieve with holes measuring 1.7 x 20 mm of sieving 16, together with the product coming from the sorting machine 12, is sent for grain separating machines 20 ( Stage III cerebrospinal fluid). After grit separation, the product from the upper collection (kernel) goes to the control separating machines 7, and the lower collections - to separating machines 15 or 22. The peeling products of the machine 19 are sent to sieving 21. Discharge from the sieve with holes diameter 4 mm of sieving 21 is returned to sieving 2. The output from a sieve with holes measuring 1.7 x 2.0 mm, sieving 21, is sent to pellet separating machines 22. After grazing machines 22, the product from the upper sieve (kernel) is sent to the sieve, and from the lower sieve to sieving 2. The husks are winnowed on aspirators 3 , 11 and 17, is sent for control (not shown in the drawing). Flour and crushed grains sown on sieves 2, 10, 16 and 21 and sorting machines 4, 9, 12 and 18 are also submitted for control.
Due to the fact that the size of buckwheat grains varies widely, the technological process of the buckwheat plant currently provides for mandatory sorting (preliminary and final) of buckwheat into six fractions using sieving machines or grain sorting machines, followed by peeling each fraction of buckwheat separately on roller deck machines. The kernel is also isolated fractionally in sieving, which requires a developed technological process. These are the main features of the existing technological process for the production of buckwheat.
When preparing buckwheat grain for processing into cereal, after cleaning it is subjected to hydrothermal treatment, including the operations of steaming, drying, and cooling.
The automatically controlled grain steaming apparatus A9-BPB is designed for steaming buckwheat, millet, oats, wheat, rice, etc.
The body of the apparatus serves as a vessel for steaming grain. There is a coil located inside the body to distribute steam evenly. The body is mounted on a frame. A loading gate is installed on the lid. Loading and unloading gates are equipped with independent drives. The electrical equipment of the apparatus consists of electric gate drives, limit switches that fix the rotation of the gate plugs by 90°, a level indicator that controls the upper and lower levels of grain when loading and unloading the apparatus, two valves with electric drives for supplying and releasing steam, and a control panel.
The control panel is designed for remote automatic control of basic operations. The electrical circuit provides two modes for controlling the operation of the device: manual and automatic. The manual mode is used to set up the operation of the device, practice operations, modify the product in emergency situations, and to control the operation of the device in case of automation failure. The main operating mode is automatic.
The grain is loaded into the vessel of the apparatus, steamed for 1 ... 6 minutes depending on the type of grain and unloaded through the unloading gate.
Acceptance tests of the A9-BPB apparatus were carried out in the hydrothermal department of the buckwheat workshop of the Bryansk bakery plant. During testing, the device was set to the operating mode recommended based on the results of the first stage of testing: the steaming time was counted from the moment the steam was released into the vessel of the device. In addition, the cycle duration was reduced due to a more rational combination of operations: opening the steam inlet valve and steaming; steaming and closing the steam inlet valve; opening the steam release valve, releasing steam. The cycle time was 492 s. Tests have shown that at a pressure in the steam line of 6 105 Pa, the set pressure in the vessel is reached in 1 min 45 s.
The quality of steaming in a given mode during testing of the A9-BPB apparatus was controlled both by the uniformity of heating and grain moistening, and by the color, taste and smell of the resulting cereal.
The tests carried out confirmed that the unevenness (deviation between the extreme values of indicators) of the distribution of moisture in the grain varies within 0.3...1.6%. The same indicator, based on the arithmetic mean value, does not exceed 0.2...0.3%. As a result of steaming, the humidity of buckwheat increased on average by 3.7...4.4% (range of fluctuations from 3.4 to 4.9%). Consequently, grain moistening throughout the entire volume of the apparatus vessel occurs quite evenly. The data obtained during the tests are shown in Table 6.
Annual economic effect from using one A9-BPB device instead of a G.S. steamer. Nerusha is 4 thousand rubles.
Another effective device in the scheme of hydrothermal processing of buckwheat is the A1-BS2-P steam dryer.
The A1-BS2-P steam dryer is designed for drying cereal grains that have undergone hydrothermal treatment. The dryer consists of the following main parts: grain receiver, heating sections, unloading section with a drive.
The grain receiver is used to distribute grain evenly along the length of the dryer. It is a steel box with dimensions 198 x 376 x 650 mm. There are two receiving pipes on the grain receiver cover. To maintain a constant grain level, there are electronic level sensors.
Heating sections serve to dry grain with heat released by steam through the heating surface. Each section consists of a collector having two chambers - steam and condensation, into which cylindrical and oval pipes are welded in a checkerboard pattern (21 pipes per section). Cylindrical seamless pipes running inside the oval ones are connected to the steam chamber, and the oval pipes are connected to the condensation chambers.
The collectors of the heating sections are connected to each other by roller pipes supplying steam and condensate from the upper sections to the lower. On both sides inside the heating sections there are inclined sloped planes that prevent grain from spilling out of the dryer and at the same time form channels for air circulation.
For inspection, cleaning and repair of parts inside the dryer, there are doors on both sides of the sections. Each heating section has on one side 60 holes Ø 20 mm (15 on one door) for sucking outside air into the dryer, and on opposite side- diffusers to remove humidified air from the dryer. The amount of air sucked from each heating section is adjusted by changing the size of the outlet slot. The unloading section serves as the base on which the heating sections are mounted.
The supporting structure of all ten heating sections are two supports located on the frame on both sides of the dryer. The unloading section has eight bins and a chain conveyor, which consists of two chains connected by scrapers. The upper branches of the conveyor move along guides, and the lower ones move along the bottom, which is made up of pull-out pallets. The chain conveyor is driven by an electric motor through a worm gearbox. The speed of the chain conveyor is controlled by a variator using a handwheel.
After hydrothermal treatment, the grain enters the grain receiver, from where, under the influence of gravity, it falls down into the heating sections. To remove moisture from grain, the dryer uses the principle of contact drying, i.e. heat is transferred to the grain directly from the heated surface of the oval pipes between which it moves. The moisture evaporated from the grain is absorbed by the air and removed from the dryer along with it. After passing through the heating sections, the dried grain enters the bunkers of the unloading section and goes out to the platforms, from which it is removed by scrapers of the chain conveyor and transported by its lower branch to the outlet.
The dryer's performance and grain drying exposure depend on the speed of the chain conveyor, controlled by a V-belt variator.
Dry saturated steam is used to heat the pipes of the heating sections. The steam pressure in the pipes and its temperature are controlled by a pressure reducing valve. The steam pressure in the dryer is controlled with a pressure gauge. Waste steam and condensate from the dryer are removed through a condensate drain.
Technical characteristics of the dryer A1-BS2-P
Productivity on natural grain 570 g/l at 56...60
reducing the humidity of steamed grain by 7...9%, t/day
Steam consumption per 1 t%, kg/h 5 5 0... .65 0
Steam pressure, Pa Up to 3.43 105
Air consumption per 1 t%. moisture removal, m3/h 200
Aerodynamic resistance, Pa 137.2
Conveyor chain movement speed at design 0.061...0.067
productivity, m/s
Fan drive motor VCP No. 6:
power, kW 7.5
rotation speed, s-1 (rpm) 24.3 (1460)
Conveyor drive motor:
power, kW 1.1
rotation speed, s-1 (rpm) 15.5 (930)
Gearbox:
type RCHU-80
gear ratio 31
Dimensions, mm:
width 810
height 8100
Weight, kg 5760
A new method for producing buckwheat was tested at the cereal plant of the Bryansk flour mill of bakery products. The planned daily productivity of the plant during the test period was 125 tons/day with a basic grain yield of 66%.
During testing, the kinematic parameters of the main process equipment were characterized by the following values:
peeling machines with rubber-coated rollers A1-ZRD (four systems) - peripheral speed of high-speed rolls 9... 12 m/s and the ratio of peripheral speeds of high-speed rolls to low-speed ones 2.0... 2.25;
ZRM sieves (four systems) - oscillation frequencies of sieve bodies 2.3...2.6 s-1 (140...156 rpm) and radii of circular oscillations of the bodies 25 mm;
grain sorting A1-BKG (three systems) - oscillation frequency of sieve bodies 5.3...5.6 s-1 (320...340 rpm) and amplitude 9 mm;
grain separators A1-BKO-1.5 (six main systems and two control ones) - oscillation frequency of sorting decks 2.8...3 s-1 (170...185 rpm) and amplitude 28 mm.
Technological performance indicators of A1-ZRD machines for peeling buckwheat grain indicate that the peeling coefficient was not lower than that achieved in practice when peeling buckwheat on roller deck machines. At the same time, the amount of crushed kernel in relation to the mass of the product entering the machine did not exceed 1.14% in all systems, which is significantly lower than that obtained in practice (2...3%) and provided for by the Rules for organizing and maintaining the technological process at cereal factories (1.5...2.5%) when peeling buckwheat on roller deck machines. The core integrity coefficient averaged 0.96.
The amount of product supplied to A1-ZRD machines when operating at a capacity of up to 3000 kg/h has virtually no effect on the quality of peeling.
The peeling products after the A1-ZRD machine of each system are sent to sieving screens to isolate the kernel, process and meal. In addition to these products, the sieves of the 1st, 2nd and 3rd systems received the lower discharges of the corresponding grit separating machines.
After sorting on sieves by passing through sieves with openings of 4.0 mm and leaving sieves with openings of 1.7 x 20 mm, a product with a small content of unhulled grain was obtained, which, after winnowing, was sent to separate the kernels to the A1-BK0 separating machines. The product obtained from sieves with holes diameter 4.0 mm and containing a significant amount of unhulled grain, after winnowing and additional sifting in grain sorting machines, where another amount of kernel was taken from it, was fed to the A1-ZRD machines of the subsequent peeling system.
The work of sieves for sorting buckwheat peeling products is characterized by the fact that 65.8... 74.9% of the product is obtained from sieves with holes Ø4.0 mm total number with a core content of 26...34.24%. The product obtained from sieves with holes measuring 1.7 x x 20 mm consists mainly of kernels with a content of unhulled grain up to 9.6%.
When sorting dehulled products at sieving and grit sorting, the content of unhulled grains and impurities increases as the product moves through the systems.
From the sieves (sieves with holes Ф4 mm) after preliminary winnowing, from 10 to 19.3% of the kernels were additionally isolated in grain sorting. The content of unhulled grains in this product, depending on the system, ranged from 5.36 to 7.68%. The yield of sieves with holes Ø 4 mm, received by A1-ZRD machines, was 80...90% and contained 27.80...30.00% of kernels, which indicates the possibility of further improving the process of sorting peeling products.
The kernel from the product obtained from sieves with holes measuring 1.7 x 20 mm in sieves and passing through sieves Ø4.0 mm was extracted in grain sorting machines using A1-BKO grain separating machines. At the same time, machines b, 14, 20, 8 and 15 worked on the preliminary extraction of the kernel, and machines 7 and 22 - on the final control of the cereal.
Technological indicators characterizing the operation of grain separating machines for preliminary kernel extraction and final control of grain show that 40.0...58.8% (extraction coefficient) of the initial product entered the upper exit. At the same time, the content of unhulled grains in the upper gathering was in the range of 0.32...0.52%.
An analysis of the operation of grain separating machines shows that there are certain reserves for increasing the efficiency of their operation. The grain separating machines operating to control the upper discharges ensured the production of buckwheat that met the requirements of the first grade. In this case, up to 51% of the grain was extracted from the total amount of product supplied to these grain separators. It should be noted that when the A1-BKO grain separating machines operated during preliminary and final control of grain, a small amount of impurities entered the upper exit, despite its high content in the original product. The main amount of weed impurities entered the lower exits.
As a result of long-term technological tests and determination of qualitative and quantitative performance indicators of the main equipment, it was established that the main advantage of the new method of producing cereals compared to the used technology is a reduction in crushing
kernels in the process of processing buckwheat into cereal and increasing its overall yield.
This is also confirmed by a comparison of cereal yields (Table 2) obtained by processing buckwheat of similar quality (new method and existing technology).
The increased yield of first-grade cereal and the overall yield of cereal with the new method of its production is obtained by reducing the crushing of the kernel.
Using data obtained from comparative tests of existing and new technologies for the production of buckwheat, it is possible to determine the final difference between all types of cereals obtained from one ton of buckwheat (Table 3). It follows from the table that as a result of improving the grade of cereal and increasing its overall yield, the cost of cereal with the new method increases by 16.75 rubles. (367.82 - 351.07). The comparable annual volume of buckwheat processing in the compared options is taken to be 37,770 tons.
The economic effect as a result of improving the grade and increasing the yield of cereals will be 37,770 16.75 0.692 = 437,792 rubles. in year. At the same time, operating costs as a result of replacing wear-out rubber-coated rollers on A1-ZRD peeling machines (based on the service life of one pair of rollers for only 70 hours) increase by 40,832 rubles. The total economic effect from using a new method for producing buckwheat at one cereal plant with a capacity of 125 tons per day will be 396,960 rubles. (437792-40832).
Based on the tests of a new method for producing buckwheat, the Kharkov PZP developed a project for the reconstruction of a buckwheat plant with an increase in its productivity to 160 tons/day and a grain yield of up to 70%, in which hulling machines with rubber-coated rollers A1-ZRD and grain separating machines A1-BKO were used , aspirators with a closed air cycle, sifters, grain sorters, etc.
As a manuscript
COMPLEX TECHNOLOGY FOR BUCKWHEAT PROCESSING
WITH HUSK DISPOSAL
Specialty 05.18.01 – “Technology of processing, storage and
cereal processing, legumes, cereal products,
Dissertations for an academic degree
candidate of technical sciences
Moscow – 2008
The work was carried out at the State educational institution higher professional education "Moscow State University food production».
Scientific adviser:
Official opponents: Doctor of Technical Sciences, Professor
Candidate of Technical Sciences, Professor
Lead organization: State Scientific Institution "All-Russian Research Institute of Grain and Its Processing Products"
Scientific Secretary of the Council Ph.D.
GENERAL DESCRIPTION OF WORK
Relevance of the topic
The production of cereal crops (millet, buckwheat, rice) totals about 1.6 million tons, and the area is about 2.9 million hectares (4.8% of the total grain crops). The largest share among them by area is occupied by buckwheat.
Cereal products occupy a worthy place in the human diet due to their varied assortment, availability to different segments of consumers, high quality And nutritional value, safety, creation of products based on them with a given composition and properties.
Buckwheat occupies a special place among cereal crops. Due to their high nutritional and biological value, products made from buckwheat are widely used not only in public, but also in children's and dietary nutrition.
Buckwheat is most widely used in the form of cereals. Products are used to a much lesser extent instant cooking from buckwheat - flakes, as well as flour. There are no instructions on the production of such products in regulatory and technical sources, and in literary sources There are conflicting and insufficiently substantiated recommendations for the production and use of buckwheat flakes and flour.
The main directions of development of equipment and technology for cereal production are: rational use potential of cereal grains; expanding the range of cereal products, improving their quality and nutritional value; improving the quality of the traditional assortment of cereals, increasing its yield; studying the properties of secondary raw materials for cereal production and methods of their rational use, etc.
Purpose and objectives of the study
Purpose of this work is the development of a comprehensive technology for processing buckwheat with utilization of husks.
To achieve this goal, it is necessary to solve the following tasks:
To justify and develop methods for producing buckwheat flakes, with the possibility of their implementation at existing buckwheat factories;
Assess the influence of technological stages and modes of recommended methods on the quality of buckwheat flakes;
To determine the nature of the proposed technological solutions for possible biochemical changes in buckwheat during its preparation for flattening, to establish rational modes of the technological process;
Develop a method for producing flour from unhulled buckwheat seeds;
To study the influence of methods of hydrothermal treatment of buckwheat on the production process and quality of buckwheat flour;
Scientific novelty
A comprehensive technology for processing buckwheat has been substantiated and developed, protected by a number of patents and providing for the production of traditional products - cereals, as well as instant products, flour and utilization of husks.
The main patterns have been identified, the parameters of hydrothermal treatment of buckwheat have been determined depending on the directions of its further use.
Technological schemes and parameters for the production of instant products, both from buckwheat seeds and cereals, have been scientifically substantiated and developed, including the use of intensive energy supply methods (IR treatment, steaming), ensuring increased yield, strength, and reduced cooking time of buckwheat flakes .
Taking into account the analysis of the structure of the kernel and changes in structural and mechanical properties during hydrothermal processing of buckwheat, a new technology for the production of buckwheat flour has been substantiated and developed, which makes it possible to produce flour from whole buckwheat seeds without preliminary fractionation and peeling. Based on a study of the effect of moistening and steaming buckwheat before grinding on the overall yield and quality of flour, recommendations for the selection of the main modes of hydrothermal treatment are substantiated.
Based on the theory of layer-by-layer movement of bulk materials during separation on sieves, a technological method has been developed for stabilizing the thickness of the buckwheat layer on a sieve during fractionation due to a circulating flow in order to increase the efficiency of the calibration process.
In order to utilize buckwheat husks, taking into account the requirements for the dimensional characteristics of the organic filler and its physical and chemical properties a technological sequence has been developed for the preparation of buckwheat fruit shells for inclusion in composite packaging materials.
Practical significance
Based on the research, technological schemes have been developed and operation parameters have been recommended that make it possible to obtain buckwheat flakes from both whole buckwheat seeds and kernels.
The developed technology is protected by RF Patent No. 000 “Method for producing grain flakes.”
Basic recommendations for conducting the technological process of producing buckwheat flour have been formulated. The possibility of using buckwheat flour obtained using the developed technology in the recipe for bread from wheat flour top quality.
A method for fractionating buckwheat has been developed, which increases the efficiency of sowing small fractions of buckwheat, which makes it possible to improve the quality of cereals as a result of a significant reduction in the content of unhulled buckwheat seeds in it. This method is protected by RF Patent No. 000 “Method for producing buckwheat.”
The possibility of using buckwheat husk as a filler in composite packaging materials has been shown. The initial requirements for agricultural waste as a raw material for the production of composite packaging materials have been developed.
Approbation of work
The main results of the work were reported at the VIII All-Russian Conference of Young Scientists with International Participation “Food Technologies” (Kazan, 2007); 5th anniversary school-conference with international participation “Highly effective food technology, methods and means of their implementation" (Moscow, 2007); VIth International scientific conference students and graduate students “Engineering and technology of food production” (Republic of Belarus, Mogilev, 2008).
The results of the work were demonstrated at the VIII Moscow International Salon of Innovation and Investment (2008) and at the II International Exhibition and Congress “Advanced Technologies of the 21st Century” (Moscow, All-Russian Exhibition Center, 2008)
Publications
Structure and scope of work
The dissertation consists of an introduction, a literature review, an experimental part, conclusions, a list of references, and applications. The list of references includes 120 sources of domestic and foreign authors. The work is presented on 202 pages of typewritten text, contains 34 figures, 32 tables.
1. LITERATURE REVIEW
The literature review provides general characteristics buckwheat, her botanical classification and morphological features, the chemical composition of buckwheat is presented. An analysis of the existing processing technology and range of products produced from buckwheat was carried out. The fundamental methods of hydrothermal treatment (HTT) of grain are considered.
2. EXPERIMENTAL
2.1. Materials and research methods
Research was carried out in the laboratories of the departments “Grain Processing Technology”, “Biochemistry and Grain Science”, “Bread and Pasta Production Technology”, “ Technological equipment bakery products enterprises" Moscow state university food production, at the department of “Technology of Packaging and Processing of Navy Materials” of the Moscow State University of Biotechnology, as well as in service laboratories.”
During the research, samples of varietal and ordinary buckwheat from four batches were used, the quality indicators of which are given in Table 1.
Technical and chemical analysis buckwheat, processed cereals, flour, bread were carried out according to the methods provided for by GOSTs in force at the time of the study.
Table 1
Quality indicators of buckwheat samples
Indicator name
Indicators
Color, smell, taste
Corresponding to healthy, benign buckwheat
Humidity, %
Pest infestation
Not found
Filminess, %
The amount of water- and salt-soluble protein fractions was determined by a method based on the interaction of protein with pyrogallol red dye; the amount of dextrins - according to the method developed by and; crumbling of buckwheat flakes - according to the method of prof. ; the average size flakes were determined using a granulometric measuring device GIU-2 and a computer software product “Flour (v3._)”; specific volume and porosity bakery products determined according to generally accepted methods.
2.2. Results and its discussion
The process of processing buckwheat into cereal has been studied by a number of researchers. Research has been carried out chemical composition buckwheat, recommended optimal regimes for its hydrothermal treatment, substantiated rational regimes for buckwheat peeling and the structure of the working parts of rolling deck machines.
IN Lately The range of buckwheat products has expanded significantly, which determines the need to develop a comprehensive technology for its processing, since the production of products such as flakes and flour is carried out at low-capacity enterprises, the raw materials for which are kernels and product obtained from buckwheat factories.
Technology has been developed complex processing buckwheat, which is schematically presented in Figure 1.
Figure 1. Scheme of integrated buckwheat processing technology
Shown in Fig. 1 scheme of complex technology involves the production of traditional products from buckwheat - cereals, as well as instant products and flour. The above scheme allows the use of specific modes and methods of GTO of buckwheat, purposefully changing the properties of raw materials for a more complete use of grain resources, increasing the yield and quality of the final products.
2.2.1. Increasing the efficiency of calibration of individual buckwheat fractions
One of the features of the buckwheat production technology is the separate processing of buckwheat into fractions. Careful sorting of buckwheat into fractions is caused by the need to achieve the highest peeling coefficient with minimal crushing of the kernel and more complete separation of the kernel from the unhulled grain. To completely isolate smaller buckwheat seeds on the sieves, the optimal height of the product layer must be ensured. It is known that, other things being equal, the efficiency of sowing the passing fraction depends on the height of the product layer on the sieve.
Therefore, it was proposed that the first part of the buckwheat fraction obtained after calibration should be sent for peeling, and the second should be returned for re-sorting on the same sieving machine. Passing through the machine again, the second part of the fraction is additionally freed from small grains. By changing the ratio of flows directed to peeling and re-screening, the optimal load on the screening machines is established.
In laboratory conditions, it was found that the amount of two large fractions when fractionated according to existing scheme amounted to
89.1% and 85.9% - when buckwheat is fractionated according to the proposed scheme (Table 2).
The developed method allows for more efficient sowing of small fractions of buckwheat. The number of additionally allocated small seeds was 3.2% compared to the traditional scheme, and the overall undersowing coefficient for fractions Ø 4.4 / Ø 4.2 and less is reduced by 18.6%.
table 2
Results of buckwheat fractionation according to existing and developed schemes
Existing fractionation scheme
Proposed fractionation scheme
Under-seeding coefficient, %
Under-seeding coefficient, %
Not determined
Not determined
Not determined
Not determined
Not determined
Not determined
2.2.2. Development of technology for producing buckwheat flakes
2.2.2.1. Production of buckwheat flakes from unprocessed buckwheat seeds
Recently, the range of cereal products, including buckwheat, has expanded significantly. The production of instant products from buckwheat (flakes), as a rule, is carried out from cereals, and the technology largely repeats the technology oatmeal. But the structural and mechanical properties of oat and buckwheat kernels differ significantly, which requires intensified hydrothermal treatment of the buckwheat kernel before flattening. Such processing may involve various modes and a combination of GTO methods.
In preliminary experiments, a rational sequence for the production of buckwheat flakes was determined: separation of the buckwheat fraction, cleared of weed and grain impurities => moistening and refrigeration => steaming, drying, cooling => peeling of buckwheat, flattening, drying of the flakes. It has been established that pre-humidification should be carried out up to 25%, and refrigeration should be carried out for 6 hours.
It was revealed that steaming modes have significant influence on the granulometric composition of the flakes. Reducing the steam pressure (up to 0.1 MPa) and reducing the steaming duration (up to 3 min) leads to a significant increase in the proportion of the large fraction of flakes in total mass compared to traditional cereal production modes (steam pressure - 0.25 MPa, steaming duration - 5 minutes). However, as the steam pressure and steaming duration decrease, the crumbliness of the flakes increases.
The choice of modes of moistening and defoliating buckwheat when preparing it for flattening was carried out using a full factorial experiment
PFE – 22. The degree of pre-wetting (X1) varied in the range of 23 and 27%, and the duration of dampening was within 5 and 8 hours.
The process was optimized based on the yield of the coarse fraction of buckwheat flakes - leaving the Ø 4.0 sieve (Y1) and crumbling (Y2). Based on the data obtained, the following regression equations were calculated:
Y1 = 61.6+ 7.6*X1 +0.55*X2 + 0.05*X1*X2 (1)
Y2 = 10.7 – 2.6*X1 +0.73*X2 + 0.78*X1*X2 (2)
The coefficients of X2 and interfactor interaction in the equations are insignificant. Obviously, this is due to the fact that the value of the cooling duration at the central point of the experiment corresponds to its optimum.
An increase in the degree of moisture has a positive effect on the quality of buckwheat flakes, namely, the amount of large fraction of the flakes increases, and resistance to mechanical stress increases. However, buckwheat moisture content above 26% leads to the formation of conglomerates as a result of the sticking together of several kernels during flattening.
It was found that tempering for two hours before the peeling stage has a positive effect on the resistance of flakes to destruction, which was indirectly determined by the crumbability index (Table 3). The content of the large fraction of buckwheat flakes after destruction compared to the control sample increases by 10.4%, and the amount of additionally formed crumbs and flour (crumbiness) decreased by 6.3%.
Table 3
The influence of different buckwheat conditioning options on the yield and
crumbliness of flakes
Yield of flakes, %
Preparation option
No tempering
(control)
Tempering
Tempering + 2nd steaming
*PP - products obtained after flattening;
**PR - products obtained after determining the crumbiness of the flakes.
2.2.2.2. Production of buckwheat flakes using infrared treatment
The IR irradiation method is well known and sufficiently studied physical method processing food products. However, IR treatment is typically used at the final stage of cereal flake production.
When carrying out the research, the following hypothesis was developed: moistening and defoliating buckwheat prior to treatment with infrared radiation leads to the saturation of the kernel with moisture and contributes to its uniform distribution in the grain. When moisture penetrates into the kernel, microcracks form in the endosperm. Subsequent IR treatment promotes the evaporation of the highly mobile moisture of buckwheat and further destruction of the endosperm and the formation of its porous structure. This leads to deeper penetration of moisture and steam into the kernel during steaming, promoting significant plasticization of buckwheat before flattening.
Testing the hypothesis showed that the inclusion of IR treatment in the technological scheme for the production of buckwheat flakes led to significant drying of the buckwheat, so a stage of re-wetting and re-wetting was provided.
It has been established that the use of IR treatment in the production of buckwheat flakes contributes to their strengthening; the large fraction of the flakes is less susceptible to destruction. Compared to the option that does not include IR treatment, the amount of coarse fraction after determining the crumbability increased by 20%.
When studying the effect of the duration of IR treatment on the yield and crumbability of flakes (Fig. 2), it was revealed that increasing the duration of IR treatment over 30 s has virtually no effect on the overall yield of flakes, but significantly affects the crumbability, making the flakes more brittle.
Figure 2. Effect of IR treatment duration on the yield and crumbling of buckwheat flakes
Buckwheat flakes that are most resistant to mechanical stress can be produced by processing for 25-35 s at a radiant flux density of 25.7 kW/m2.
It has been experimentally established that when the intensity of IR radiation decreases, it is necessary to carry out longer processing, achieving a greater reduction in the moisture content of the semi-finished product. Obviously, this is due to the fact that at a radiant flux density of 25.7 kW/m2, the evaporation of highly mobile moisture in buckwheat occurs more intensely, which leads to a more significant loosening of the endosperm.
2.2.2.3. Production of buckwheat flakes from kernels
The possibility of producing buckwheat flakes and kernels has been studied. The initial raw material was buckwheat, which underwent GTO under traditional cereal production regimes. In the first case, buckwheat peeling was carried out at the final stage of preparation, that is, before flattening; in the second case, immediately after cooling the buckwheat, that is, the kernel was directly prepared for flattening.
Steaming buckwheat at a steam pressure of 0.25 MPa for 5 minutes. leads to a significant strengthening of the core and a decrease in the strength of the flakes. It has been established that increasing the duration of re-wetting (TPOTV) reduces the crumbability of buckwheat flakes (Table 4).
Table 4
The influence of the duration of re-wetting on the yield and stability of flakes
Yield of flakes, %
Flakes obtained by GTO of buckwheat seed
Flakes obtained from GTO kernels
TPOTV. = 6h
TPOTV. = 12h
TPOTV. = 18h
TPOTV. = 6h
TPOTV. = 12h
TPOTV. = 18h
It is recommended to shell buckwheat immediately before flattening; the amount of large fraction of buckwheat flakes in this case is one and a half times greater than when shelling buckwheat after completion of the GTO, provided for by the traditional cereal production scheme.
2.2.2.4. Determination of the quality characteristics of the produced flakes
Based on the overall yield of flakes, their granulometric composition and crumbability, 6 technological schemes for the production of buckwheat flakes were identified, which made it possible to obtain flakes characterized by the best performance. For buckwheat flakes produced according to these technological schemes, the characteristics given in Table 5 were determined, which were also determined for whole buckwheat seeds and kernels, which were the control.
Table 5
Qualitative characteristics of produced buckwheat flakes
Index
Whole buckwheat seed
Buckwheat flakes produced by technological scheme
From buckwheat seeds
From buckwheat seeds with tempering
From buckwheat seeds with tempering and steaming
From buckwheat seed with IR treatment
From buckwheat subjected to GTO
From the kernel
Total yield, %
Cruelty, %
Average size, mm
Cooking duration, min
Weld coefficient, y. e.
Humidity, %
Total protein;
Starch;
Dextrins.
*in brackets - the total yield of buckwheat flakes in terms of whole buckwheat seed;
**according to literature data
The total yield of buckwheat flakes for all variants of technological schemes is at least 95% in relation to the cereal used for flattening, or at least 71% in relation to buckwheat. The exception is the option of producing flakes from kernels.
Considering the indicators of the set of characteristics given in Table 5, the best option the scheme for the production of buckwheat flakes, which involves infrared treatment, should be recognized. These flakes are distinguished by one of the minimum crumbliness indicators and the maximum average flake size. The decrease in the amount of water- and salt-soluble protein fractions in this sample is not as noticeable as in other cases and amounts to 6.3%. As a result of the complex effects of humidification, IR treatment and steaming, the amount of dextrins increases to 2.6%.
From the point of view of consumer benefits, flakes produced using infrared processing are characterized by a minimum cooking time of 2 minutes and a weld coefficient of 6.5-7.5 conventional units.
Figure 3. Technological scheme for the production of buckwheat flakes using IR treatment
2.2.3. Development of technology for the production of buckwheat flour
The production of buckwheat flour is usually carried out from cereals and is associated with significant costs, since it involves the processes of calibration and fractional peeling of buckwheat. One of the tasks was to develop a technological scheme that eliminates these processes.
Taking into account the structure of buckwheat, as well as based on the study of the content of the buckwheat kernel in intermediate grinding products, their aerodynamic properties, a technological scheme for grinding buckwheat into flour using aspirators was developed, presented in Figure 4. The technological scheme allows obtaining a yield of buckwheat flour in an amount of at least 70 %.
The technological process for the production of buckwheat flour includes cleaning the grain from impurities, grinding, sorting of grinding products, and flour control.
Figure 4. Technological diagram for the production of buckwheat flour
In order to increase the yield of buckwheat flour and more fully utilize the potential of buckwheat, the influence of GTO methods and modes was studied, the effectiveness of which was judged on the basis of the total yield of buckwheat flour, as well as the residual starch content in the husk after grinding. The results are shown in Table 6.
Table 6
The influence of GTO methods and modes on the yield of buckwheat flour
GTO modes
Total yield of buckwheat flour, %
Humidification by 3%; cooldown duration – 15 minutes.
Steaming at steam pressure (p) 0.05 MPa; for (t) - 2 min.
Steaming at
p = 0.05MPa; t = 5 min.
Steaming at
p = 0.25MPa; t = 2 min.
Steaming at
p = 0.25 MPa; t = 5 min.
It has been established that steaming buckwheat, depending on the adopted GTO parameters, makes it possible to achieve a more complete yield of the kernel and increase the yield of flour by 0.5-1.5%. Before grinding, it is advisable to steam the buckwheat at a steam pressure of 0.05 MPa for 5 minutes. A further increase in steam pressure does not lead to a significant increase in the yield of buckwheat flour.
The feasibility of steaming buckwheat before grinding was experimentally confirmed when assessing the influence of different dosages of buckwheat flour on the quality of bread made from premium wheat flour. The quality of bread was assessed using a scoring method. The results of determining the quality of bread are presented in Figure 5.
The quality of bread using flour obtained from steamed buckwheat increased by 2–15% compared to bread using flour from unprocessed buckwheat and by 8–38% compared to bread without the use of buckwheat flour.
Figure 5. The influence of the amount of added buckwheat flour on the quality of bread made from premium wheat flour
Bread using buckwheat flour from seeds that had undergone GTO had a more attractive appearance, due to a more saturated color of the crust, a larger specific volume, a more developed porosity structure, and a more pronounced pleasant buckwheat aroma.
2.2.4. Disposal of husks
Creation waste-free production with the fullest use of raw materials, including waste, still remains relevant. Secondary raw materials and waste from the grain processing industry annually amount to about 5 million tons. One of the areas integrated use secondary raw materials resources of the agro-industrial complex and the introduction of environmentally friendly methods of their disposal may be the use of secondary raw materials in packaging production.
The properties of packaging composite materials depend on the particle size of the organic filler, which should not be more than 450~500 microns, but not less than 100 microns. The quality of the product also depends on the moisture content of the raw materials. The humidity of the raw materials should not be more than 10%.
The husks were crushed in impact-abrasive machines. During the research we tested Various types machines (roller machines with threaded and micro-rough surfaces), Brabender knife crusher, EML, MShZ, Pertena mills.
It has been established that single grinding in machines with a peripheral speed of the working body of at least 80 m/s and a sieve shell hole diameter of 450 microns makes it possible to obtain 95% of the product with a particle size of less than 450 microns.
The waste preparation process is presented in Figure 6 and includes:
1. Removal of crushed kernels and meal, which are a feed product and are used in feed production.
2. Drying the husks to 10%, which is possible when drying them in a liquefied state (laboratory dryer at T = 110 ºС for 3 minutes).
3. Grinding of husks with control of grinding coarseness in a sifting machine.
Figure 6. Schematic diagram of the process of preparing husks for insertion into composite packaging materials
Obtained after grinding buckwheat husk is a filler; polyethylene or polypropylene was used as a polymer in the production of composite packaging materials.
The production line included the production of granules by thermoplastic extrusion, after which a film was produced, which was subsequently examined for breaking stress.
It was found that the more waste the polyethylene matrix contained, the lower its failure stress. Similar results were obtained for the polypropylene matrix. However, if we take into account that in order to create high-quality secondary polymer raw materials and products based on it, the strength value, characterized by the breaking stress in uniaxial tension, must be at least 4 MPa, then for a composition prepared with propylene waste, the dosage of introducing buckwheat husk can be 20% .
1. A comprehensive technology for processing buckwheat has been developed, providing for the production of both traditional products - cereals, and instant products, flour, as well as the disposal of husks.
2. As a result comprehensive research technologies for processing buckwheat into instant products (buckwheat flakes) and baking flour, new technological solutions for the production of these products with increased yield have been proposed.
3. When producing buckwheat flakes, it is recommended next sequence and modes of technological operations: the buckwheat fraction, cleared of impurities, is brought to a humidity of 26-27% and left for 6-7 hours, exposed to IR radiation for 30-35 at a radiant flux density of 25-26 kW/m2. After this, additionally moisten to 26-27% and leave for 6-6.5 hours, then steam for 5 minutes at a steam pressure of 0.1-0.15 MPa. Dry the steamed buckwheat to a moisture content of 26%, cool, and peel. At the final stage, remove crumbs and flour from the buckwheat flakes obtained after flattening, and bring the flakes to a moisture content of 12-14%.
4. The possibility of using two methods of energy supply simultaneously in the production of buckwheat flakes - IR radiation and steaming - is theoretically justified. Experimental studies have confirmed the effectiveness of sequential treatment of buckwheat with infrared radiation, leading to some loosening of the kernel structure, followed by steaming, which promotes its plasticization. The use of this technology leads to a reduction in the crumbliness of the flakes, the cooking time is no more than two minutes, and the welding coefficient reaches 7.5 cu. e. The total yield of flakes is about 97% in relation to the cereals used for flattening, or 71.6% in relation to buckwheat. The decrease in the amount of albumin and globulin in such flakes is minimal and amounts to 6.3%, the amount of dextrins increases to 2.6%.
5. The regimes for preparing buckwheat, which has undergone GTO under traditional cereal production regimes, for flattening to produce flakes have been experimentally substantiated. It is recommended to select buckwheat for flake production before the peeling stage. Preparation for flattening should be carried out in accordance with the scheme for producing flakes from buckwheat seeds, and the re-wetting stage should be provided for at least 18 hours.
6. The developed technological scheme for the production of buckwheat flour does not provide for the stages of fractionation and peeling and makes it possible to obtain a total flour yield of at least 70%.
7. The modes of GTO of buckwheat in the production of flour are scientifically substantiated and experimentally confirmed. It is recommended to carry out preliminary steaming at a steam pressure of 0.05 MPa for 5 minutes, which helps to increase the flour yield by 1.1%. At the same time, the content of the large fraction of buckwheat flour increases, resulting in the strengthening of the buckwheat kernel during steaming.
8. The possibility of using buckwheat flour produced according to the developed technological scheme in the recipe for bread made from premium wheat flour is shown. Noted positive influence buckwheat flour on the quality of bread. The quality indicators of bread obtained using buckwheat flour subjected to GTO are better than those of bread using unprocessed buckwheat flour and bread without the addition of buckwheat flour. The recommended percentage of sub-sorting of buckwheat flour is 15 – 20%.
9. A method for fractionating buckwheat has been developed, which involves stabilizing the load and thickness of the buckwheat layer in sifting machines, by dividing the small fractions of buckwheat from sieves into two parts, one of which is sent for peeling, and the second for re-sifting on the same sieves. Application this method during fractionation, it makes it possible to additionally isolate more than 3% of small buckwheat seeds compared to the traditional fractionation scheme.
10. In order to utilize buckwheat husks, a technological sequence has been developed for preparing it for its introduction into composite packaging materials, including the stages of removing feed waste from buckwheat fruit shells, drying and grinding the husks. The possibility of using buckwheat husks in composite packaging materials is shown. For a composition prepared with propylene waste, the dosage of introducing buckwheat husks can be 20%.
1. Chevokin, buckwheat flour production [Text] / , // Collection of reports of the IV International Scientific and Practical Conference “Technologies and Products” healthy eating" - M.: Publishing complex MGUPP, 2006. – Part II – pp. 64-67.
2. Izosimov, modes of hydrothermal treatment on the quality of buckwheat flakes [Text] / , // Materials of the third international conference “Quality of grain, flour, bakery and pasta products” - M.: Pishchepromizdat, 2006. – P. 111-112.
3. Chevokin, A. Technology for producing buckwheat flakes [Text] / A. Chevokin, V. Izosimov, E. Melnikov // Bread products – No. 6. –
pp. 48-49.
4. Chevokin, buckwheat flakes using intensive energy supply [Text] / // Collection of reports of the 5th anniversary school-conference with international participation “Highly efficient food technologies, methods and means of their implementation” - M.: MGUPP, 2007. – P. 330-333.
5. Melnikov, obtaining grain flakes [Text] / , // RF Patent No. 000. – 05.20.2008. - Bull. No. 14.
6. Kolpakova in the food industry - a promising raw material for biodegradable packaging compositions [Text] /, etc. // Food industry– No. 6. – pp. 16-19.
7. Chevokin, A. The influence of preparing buckwheat for flattening on the quality of flakes [Text] / A. Chevokin // Bread products – No. 7. – pp. 54-55.
8. Melnikov, obtaining buckwheat [Text] / , // RF Patent No. 000. – 09/10/2008. - Bull. No. 25.
9. Ananyev, No. 000 Biologically degradable thermoplastic composition [Text] /, Pankratov G. N. - No. stated 02.28.2008.
Complex buckwheat processing technology with hull recycling.
A. A. Chevokin
Results of complex buckwheat processing technology development are presented in the paper, assuming production of fast preparation products and buckwheat flour; improvement of traditional groats quality; Hull recycling.
Basic regularities are revealed; depending on directions of buckwheat further use parameters of its hydrothermal treatment are defined.
Main recommendations on technological process conducting of the aforementioned products manufacture are formulated.
The INTEK company has begun implementing a project for the manufacture and installation of an automated line for processing buckwheat into cereal in the Kursk region.
The grain processing plant is designed for processing buckwheat grain into quick-cooking cereals - kernels and processed.
Actual yield of cereals using the proposed technology
from grain of basic condition GOST 19092 Basic yield of cereals
according to current industry standards
Whole grain - 72% Whole grain - 62%
Prodel - up to 1.5% Prodel - 5%
The production of buckwheat with the actual yield using the proposed technology is indicated provided that its quality is consistent modern requirements market, i.e. in a number of indicators it exceeds the requirements of GOST 5550.
Today, there is an operating line of our production that successfully processes buckwheat, but due to the growing demand of retail chains, the volume of buckwheat processing no longer suits the processor. The new line should significantly increase processing volumes and reduce the labor intensity of the process.
The buckwheat processing line consists of two departments: preparatory and hulling. In the preparatory department, grain is received, purified from impurities such as seeds, oats, etc. on a grain cleaning machine, and separated from various mineral impurities on a stone separating machine. Pre-drying is carried out in an electric drum dryer. In addition, a fresh air ventilation system with the ability to heat the air is installed in the preparatory department. The scheme according to which the equipment is installed allows grain to be sent to the hulling department, bypassing preliminary drying, if the humidity meets the requirements of the technological process (no more than 14.5%). The hulling department contains a grain steamer, a second dryer, a calibration machine and two hulling and sorting machines. A steam generator is also installed there.
But the main advantage of this line is its complete technological cycle, complete mechanization and excellent quality of the resulting products. All machines in this department are connected common system aspiration, grain elevators and husk exhaust ventilation.
The size of the holes of the sorting sieve is selected depending on the size of the grain in the batch to be cleaned, so that all the grain is obtained by passing, and large impurities are collected by passing. The size of the holes of the underseeding sieve of the separation system is set based on the elimination of small debris and sand by passing and obtaining grain cleared from them.
In order to better isolate small grains, and along with them small impurities, the underseeding sieve is placed with large size holes than provided state standard for small and puny grains.
The operating mode of the aspiration part of the machine must be intense enough to release the maximum possible amount of light impurity without capturing the usable grain. The air speed in the aspiration channel should be less than the speed of entrainment of buckwheat grain, but sufficient to release light impurities. The stream of purified grain is sent to a destoning machine, where it is cleaned of mineral impurities.
Then, hydrothermal treatment of the grain is carried out until peeling, which improves its technological properties and the nutritional merits of the produced cereal. Before starting work, the steamer body is heated with steam. Afterwards, 150-160 kg of buckwheat grain, purified from impurities, is poured through the loading hatch.
To better warm up the entire mass of buckwheat, it is necessary to slightly open the unloading valve so that a small amount of steam escapes through it, but the buckwheat does not spill out. After heating for 5-10 minutes, the grain is kept under a steam pressure of 2.0 kgf/cm for 5-10 minutes. The grain after steaming should have a dark brown color and a moisture content of no more than 18%. If the grain moisture content exceeds 18%, it is necessary to bring the parameters of the steam supplied to the steamer to those indicated above. In addition, it is necessary to thermally insulate the steamer body and the steam supply line to reduce steam condensation.
Drying of steamed grain is carried out in a steam dryer. Drying is continuous. The moisture content of the grain after drying should not exceed 15%. At the end of drying, the grain is sent for calibration. In order to reduce the crushing of the kernel during peeling and increase the efficiency of the shelling machines, buckwheat is sorted by size into four fractions. Sorted buckwheat grains are sent by gravity to storage tanks.
After peeling in the hulling unit, the product enters the receiving sieve, where flour is separated by a passage, and the waste - a mixture of hulled and non-hulled grains, as well as husks - is winnowed in the first aspiration channel. After winnowing, the grain mixture is freed from the fruit shells.
The most responsible process is the selection of hulled grains (kernels) from unhulled ones. If there is more than 0.3% buckwheat in the kernel, it will be non-standard. The presence of kernels in buckwheat sent for re-husking should be no more than 3.0%.
After peeling a certain fraction, the peeling products after winnowing are supplied to a sorting sieve, in which a sieve with holes 0.2-0.3 mm smaller than the sieve holes is installed on the calibration machine, from which buckwheat of a given fraction was obtained. In this case, the grains that remain unhulled cannot pass through the holes of the sieve and fall off, but the kernel passes through, since the diameter of the circle described around the largest kernel of a given fraction is less than the diameter of the holes of the sieve from which buckwheat was obtained. Unhulled buckwheat grains are sent for re-hulling.
The kernel, separated by passing through the sorting sieve, enters the underseeding sieve, consisting of two canvases. At the beginning, a sieve with 01.5 mm holes is installed, and by passing through this sieve we obtain flour. Next, a sieve with holes measuring 2.0×20 is installed. By passing through this sieve we get the job done. The kernel immediately leaves the underseeding sieve into the second channel, where it is finally winnowed from light impurities.
The source of steam for hydrothermal treatment and steam dryers is two double-circuit steam boilers operating on husks. In addition to the direct production of cereals, waste (husks) are processed into briquettes and pellets. For this purpose, a direct-flow shell dryer with furnace gases and a briquette extruder are used. Briquettes obtained from husks differ big amount heat generated during their long-term combustion and a small amount of soot released. Briquettes are ideal for frying kebabs, barbecues and other delicacies; they can be used for stove heating and fireplaces.
At the client’s request, the delivery issue was worked out buckwheat processing lines.
In this case, buckwheat processing means the preparation of buckwheat for retail sale.
As an example, we will describe a basic simple line, which consists of 2 main parts:
- Line for cleaning and sorting buckwheat by size
- Buckwheat peeling line (husking machine)
General diagram of the buckwheat preparation line (click to enlarge):
1. Cleaning and sorting line
The cleaning and sorting line is used to remove various impurities and dirt, as well as sort buckwheat into 7 grades (sizes).
Consists of inlet accumulator, purifier, bucket elevator, sizing equipment and control panel.
Cleaning and sorting process: loading > cleaning > lifting > sorting by size > grain 7 sizes
- Peeling line
The peeling line is used for peeling buckwheat of any size by changing the gap between the working elements, removing the husks, and separating the unpeeled grains from the peeled ones. Uncleaned grains are automatically returned for re-cleaning.
Buckwheat shelling equipment consists of an input storage tank, a bucket elevator, a main part (4 shelling machines, a cyclone, a husk storage tank, a husk-grain-kernel separator, a grain-kernel separator) and a control panel.
The process of peeling (peeling) buckwheat:
These 2 modules allow you to solve the basic problems of preparing buckwheat without the need to purchase additional equipment.
The equipment is characterized by low energy consumption, compactness, low percentage of damaged grains, ease of use and maintenance. This is the most optimal minimum set of equipment for processing buckwheat.
Most of the husk retains volume and can be used to stuff pillows.
The line can also be equipped with additional equipment photo sorter(machine for sorting buckwheat by color), machine for removing dust from bags, others additional equipment, and buckwheat husk processing line.
General view of the buckwheat husk processing line:
Processed buckwheat hulls are widely used for stuffing pillows and can also become an additional source of profit.
Video - processing buckwheat hulls:
More photos of buckwheat processing lines (click to enlarge):
There is also a simpler and cheap equipment for preparing buckwheat, below are some examples:
Screening and stone removal machine
Serves to clean buckwheat from sand, stones, lumps of earth and other contaminants that are heavier than buckwheat. Effective for removing dirt that matches the size of the grains. The machine is based on the principle of gravity.
Buckwheat washing machine
Serves for washing buckwheat with water and drying.
Peeling machine
Simple equipment for buckwheat husking - cleaning buckwheat groats (kernels) from husks.
Separator
Sorts buckwheat by size.
We will select for you any equipment for processing buckwheat, including lines for the production of buckwheat flour, buckwheat tea and other buckwheat products.