Un Factories Automation Systems

1. Introduction

• The role of automation in flour production process
• Increasing production efficiency, reducing error margin, 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 raw material and product storage depots.

 Applications:

• In wheat silos: Raw material stock management
• In pre-milling bunkers: Regulating the feeding process
• In flour storage silos: Product stock management and capacity control
• In by-product depots: Monitoring the levels of bran and other by-products

Used Level Sensors:

• Ultrasonic sensors - Makes contactless measurements, provides high accuracy
• Radar sensors - Can make accurate measurements even in dusty environments
• Capacitive sensors - Detects the level of solid and liquid materials
• Mechanical float sensors - Traditional but durable method

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

3. Yield Scales

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

 Working Principle:

• Yield is determined by calculating the difference between input and output scales
• Production processes are optimized by continuously monitoring with PLC and SCADA
• Data is presented to operators for detecting production errors

 Advantages:
✅ Increases efficiency in flour production process
✅ Reduces raw material waste to lower costs
✅ Provides continuous data to maintain production quality

4. Flow Weighing Scales

Flow weighing scales measure weight in production lines where raw material and products are continuously moving.

Applications:

• Control of wheat flow before milling
• Precise dosing of mixtures and additives
• Determining the amounts of by-products (bran, semolina, etc.)

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

5. Packaging Scales

Accurate packaging and preparation for shipment of the right amount of flour is crucial.

Working Principle:

• Flour comes to the weighing bunker and is filled into bags in the specified amount
• Filling and transportation are done with belt systems
• The automation system detects faulty weighings and makes necessary corrections

Advantages:
✅ Increases weighing precision
✅ Increases production capacity by fast and accurate filling
✅ Reduces human errors and loss rates

6. Process Operating 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 of packaging and shipment processes

Advantages:
✅ Ensures all processes are managed with an integrated system
✅ Detects production errors early
✅ Allows remote monitoring and control 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): All machines and sensors working interconnected
 AI-Supported Systems: Automatic error analysis and production optimization
 Big Data Analytics: Processing production data for achieving optimum efficiency
 Remote Monitoring and Control: Production monitoring through mobile apps 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 weighing scales, and packaging scales play critical roles in every stage of production.
✅ Process automations that work integrated with SCADA and PLC systems enable factories to become fully automatic.
✅ With next-generation technologies (IoT, AI, big data analytics), maximum efficiency in production is aimed.