Years of flaking experience have gone into the development of the worlds most advanced steam grain flaking system.
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What makes Flake Boss 2.0 a cut above the rest?
The Flake BOSS 2.0 is the latest generation of a revolutionary design that has changed how flaking has been approached for over the last 100 years. Our advanced system is a collection of equipment and automation applications designed to provide a superior steam flaked grain. By gathering accurate analytical data and then analyzing this information, we make precise adjustments to the various processes involved in the production of steam flaked grain, eliminating operator error and inconsistency. Our experienced designers and programmers work hard to develop a control system that provides a higher degree of quality in the finished product. Take a look at our package systems below.
FlakeBoss 2.0 Systems
Basic Control System
The World’s Most Advanced Suite of Programing Tools Ever Designed to Automate and Refine Steam-Flaked Grain Quality…
HydroBOSS Grain Moisture
Advanced microwave technology measures the moisture of the incoming grain. Adjustments are then made to the amount of water…
Flake Management System
This innovative technology will allow for the auto collection and sampling of flaked grain from both sides of the flaker machine…
Boss Automation Industrial Controls
At the preprogrammed time that the Mill’s Operator sets, the FlakeBOSS 2.0 Automation system automatically enters into Preheat mode. The PLC will open the Master Steam Safety Valve as well as the appropriate Steam Header Control Valves, while monitoring pressures and checking for malfunctions.
This allows the Steam Chest to completely finish Preheating, even before the Operator arrives at the facility: all while continuously streaming cataloged temperature and pressure read-outs; allowing it to be monitored anywhere on a laptop or mobile device.
Once the Steam Chest has arrived at the desired preset temperature, the control system can either be set to hold in preheat mode, or to automatically cycle into cook mode, where it will begin feeding the Grain into the system.
Steam Cook Control
The FlakeBOSS 2.0 automated control system continually monitors the internal temperature of the grain in the Steam Chest with advanced digital temperature monitoring technology- all while giving you a live feed on this data in one central hub. The PLC then incorporates this data into precise PID calculations and makes precise adjustments to levels, so as to provide a very consistent and thorough cooking process. Consistency in this portion of the Steam Flaking process is one of the key factors to optimizing starch availabilities in the finished product, and Flake Boss 2.0 is designed to optimize the process to the nearest degree.
All equipment is automatically started from a centralized Graphical HMI Station that is controlled by the FlakeBOSS PLC. The PLC monitors every aspect of the system to make sure that all equipment is ready to run. All ancillary equipment such as hydraulic pumps or flake conveyors are automatically started simultaneously.
Flaking Speed Control
All changes made to the Flaking Speed are controlled by the FlakeBOSS 2.0 control system and are based on accurate analytical data. This data includes Flaker motor amps, Flaking pressure (actual psi of pressure being exerted between the rolls,) Flake Density, determined by an accurate weighing process.
These analytical inputs are used in a PID formula to calculate and control feeder speed.
Flake Density Monitoring
The FlakeBOSS 2.0 Flake management system automatically pulls a sample from each side of the flaker at a pre-programmed interval. This sample is then accurately weighed in a precise and consistent manner resulting in much tighter process.
Flake Density Control
The FlakeBOSS 2.0 Flake Management system analyzes the accurately weighed sample, then determines if the flake weight or density is within the acceptable limits of the the desired flake weight. If a change is needed, the PLC sends control signals to the automated gap control equipment- which in turn automatically makes changes the size of the roll gap in small incremental amounts.
After each adjustment, a new sample is automatically pulled and analyzed for accuracy and consistency- and then archived for posterity and future reference.
The PLC monitors every aspect of the system to make sure that all equipment is ok to run.
All ancillary equipment such as hydraulic pump or flake conveyance are automatically monitored for run condition. In the event an unexpected shutdown occurs, the program will automatically shutdown the entire system in a controlled manner, and alert the operator of the problem with a variety of methods.