Cereal Processing Custom Design Services

Processing Flow Design

Satake project engineers, process engineers and project drafters are fully aware of the many, varied methods for erecting mills, cleaning plants, storage silos, packaging facilities, installing material handling systems and complying with current legislation about health and safety. When requested, Satake can offer your architects and engineers advice based upon our extensive experience. Because each customer has their own requirements, each plant is designed based upon individual design specifications. Satake can produce the right solutions, at the right time, for the right price.

Design and Contract Complete Process Facilities

In the building of a completely new plant, there is much to be considered. Satake can undertake the complex work of designing, manufacturing, procuring, erecting, and commissioning complex installations. Our technicians and engineers provide expert service at every stage from concept to the creation of the new plant. Our expertise covers the whole field of materials handling, grain processing systems, storage, packing, power supplies and building services requirements.

Satake and CPE Engineering team up to design and deliver a premiere rice mill facility in Thailand.

Consulting Services

Technical Solutions
Our team of engineers will translate customer requirements into a technical solution, defining the process and plant layout. Full consideration is given to power consumption, staffing levels, maintenance and capital costs to provide the most suitable economic package.

Analyzation of Processing Systems
Teams of Satake professional engineers are available to review and analyze existing or planned operations and offer proposals for engineered solutions for the improvement of plant performance.

Running Reconstruction
The economics of mill operation often make it necessary to maintain output even when the mill is undergoing a reconstruction and modernization program. Proper, advanced planning is coordinated by Satake to maintain continuous milling activity during the changeover period, leading to optimum output.

Remodeled Mills
Progressive milling companies seeking to improve productivity must examine the merits of a remodeled mill compared with the building of a band new plant. Often remodeling within an existing building is the most cost-effective solution. Irrespective of the location or the immensity of the task, our staff will resolve your remodeling problems for you, with step-by-step approval of each phase if necessary. A remodeled mill prepared by Satake is effectively a brand-new mill.

Field Service and Maintenance

Satake’s professional service and process engineers can assist in the development of planned preventative maintenance programs to insure greater plant performance and efficiency. In addition, Satake offers service contracts, through which our certified technicians perform scheduled maintenance on our electronic sorting machines. Participating customers experience less downtime, resulting in improved efficiency and production.

Satake USA offers Operator Training packages designed to meet customer’s specific requirements. Training of plant personnel, both process and administrative, is an effective way of improving performance and employee motivation. Discussions with the customer take place to determine the scope of the training and ways to monitor its effectiveness. Training manuals are custom prepared, covering all facets of milling operations. Both on- and off-site training is available.

Satake USA employs a team of on-site professional service engineers who respond quickly and effectively to problems both in the United States and abroad. On-site services include: emergency breakdown repair, installations, repairs, upgrades, and conversions.

Process Control

Electrical Engineering
From the transformer to the transducer, our electrical installation staff are fully conversant with industrial and national standards. LV switchboards and motor control centers are the focal point of most installations. From small control panels to MCCs housed in their own air-conditioned control rooms, our electrical engineers can supply all design and installation requirements. The design service also includes the provision of training programs and comprehensive operation and maintenance manuals. Analog and digital instrumentation are installed to measure and control many process variables; for instance: flow, level, pressure, and temperature.

Plant Automation
The move toward improvements in plant operation and efficiency has evolved around developing automatic control systems and automating mechanical and processes.

PLC and SCADA Process Control Systems
Programmable Logic Controllers (PLC’s) have evolved considerably since first being introduced. PLC control is now an accepted part of every process plant control system. Supervisory, Control, Automation, and Data Acquisition (SCADA) have similarly evolved and found favor with their increased power and capability. Programming is in many extents the final output stage of PLC/SCADA design. Our engineers are fully aware of the plant equipment and operational process requirements.

Microprocessors, industrial electronics, and software are the building blocks of PLCs. The increase in processing power, the reduction in size and the sophistication, of the three elements respectively, have produced micro PLCs with the power to handle analog signals, carry out PID control and enable fuzzy logic control strategies to be developed. There are a multitude of manufacturers in the market place. The strong competition continuously drives forward the technology. Manufacturers include; Allen Bradley, Mitsubishi, Siemens, and Cegelec. Each have their own benefits and restrictions, and quite often their own programming language. Fortunately, the adoption of IEC 1131 provides a common framework to enable a wider understanding of the different manufacturer’s specifics.

Management’s information is the feedstock of process plant operational decisions. Automation has provided process plant managers the opportunity to change production cycles and set performance parameters in time scales that would not have been possible under manual systems. In order to partition the information and plant management from the production floor control systems, the supervisory control automation and data acquisition packages have come to the fore. Most of today’s packages are in monitoring and management environments. However, the power and capability of the PC has grown to such an extent that it will be difficult for the control systems engineers to resist using this incredible processing and mathematical power in their schemes.

Man/Human Machine Interfaces
Traditional control systems use push buttons, selector switches, indicator lights and chart recorders to provide information on the plant status, and to allow operators to set the plant to work. On the other hand, SCADA packages use computers and VDU’s to achieve the same ends. A third alternative is available and is quickly gaining acceptance and wide use. This is the MMI or HMI (Human Machine Interface). Available across a wide range from simple alpha-numeric keypads with scrolling text display, to full graphical display capability with touch screen operation. The HMI provides a very cost-effective solution and simple menu-based programming provides a level of information and control that would not be possible with conventional systems.

Central Mill Pneumatic Systems
An effective and efficient pneumatic system is essential to running a successful modern mill. Satake can provide complete design and installation services for pneumatic systems. The use of the latest computer aided drafting design software allows our engineers to calculate and plan the most economic and optimized spouting routes.