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With the Gearn Flaking System you will receive value for your money and that value will prove itself over the next 20 years.
The Gearn Flaking system has evolved over the last 20 years and you will receive the benefit of what we have learned from every mill system we have ever built. We only make changes to better the product not cheapen it, this is our promise to you. If price is your main concern and not quality then the Gearn Flaking System is not going to be what you want. This does not mean our prices are out of line, but what it does mean is that there are always ways to make a product cheaper and this simply has not been our goal. When we turn a flaking system over to the customer everything will be right and as it should be. We try to make each system the very best we ever built and not necessarily just like the last one we built. The Gearn Flaking System is a very flexible product it can be moved, changed, added to, and has value much greater than it parts. This is very important down the road when changes need to be made. When a flaking system is built into concrete its value is limited to the scope of where it is placed this is not true with the Gearn Flaking System. It can be moved and sold just like a tractor or combine or moved and reconfigured to fit a changing need.
Specification of Gearn flaking system: The Gearn 24" x 48" roller mill with built in Stainless Steel peg feeder The Gearn mill is the heaviest in the industry with rectangular tubing frame, heavy steel bearing housings and best quality German rolls and shafts. All bearings have a central greasing system for ease of daily maintenance. The integrated peg feeder has a hydraulic motor for long life and precise control of grain flow to the rolls. The mill is powered by our new dual system with extra heavy duty TEFC motors for extreme duty. The belt guards are made for quick and easy removal, no bolts to remove. There is a complete rail system for handling the rolls in and out. The rolls come out the front of the mill making roll changes much easier. The average time between roll recorrugation has been over a year compared to nine months for the standard 18" X 36" rolls. This of coarse is a function of tons processed and will vary with each installation. The heavy frame of the Gearn roll makes it a very rigid machine which means a more consistent flake and a longer life machine. We go to great lengths to make sure that the rolls are absolutely parallel. The slightest amount of miss-alignment will cause flake damage. This is very important and the only way to assure alignment we provide a very heavy frame which has been machined in and not just welded up. We even did it this way until we realized what a difference it could make now all Gearn mill frames are machined to exact tolerances.
Above the above the 24" X 48" mill is a matched 68 1/2 inch diameter x 30 foot tall, fully insulated, weather proofed, stainless steel, steamchest which has optimum plug flow characteristics. Our latest design innovation has been to increase the diameter of our standard steamchest to give us a longer grain retention time. The control valves are mounted in such a way as to make it very easy to replace a valve for easy maintenance. The steamchest also has an electronic read out temperature system which measures temperature at 3 levels within the steamchest. The round chest, which we pioneered, has now become the industry standard, but no one has the round steam spurge technology that we have. This really does offer a better cook and consequently a better flake with less energy.
In the models with separate mill building it is 15 foot wide and 45 foot long giving ample room for a complete double mill package. In this space is a separate control room which is heated and air condition and houses the industrial motor controls and is the operations center of the flaking system. There is a graphic outline of the equipment which shows what equipment is in operation at any given time. All the automated functions are based within the motor control center. With each unit comes a three inch thick operations manual which gives details on the equipment in the system. The building is fully insulated even the bottom is sprayed with urethane to seal as well as insulate the building. The building has two 8' wide insulated roll up doors by Overhead Door Co*. which are very heavy duty doors and are well insulated also. The building has a forced air heating system* which will make it workable even on the coldest days. The base of the building is two 18" by 50# I beams which is as strong of a foundation you could ask for in any building. The I-beam substructure lets us place the building in about any location and still be self supporting.
The boiler building is 34 foot long by 15 foot wide and has exactly the same construction and features of the mill building but has no control room. The boiler building houses the boiler, the soft water system, the boiler water make-up system which has a large capacity pre heated make-up tank. The boiler system is complete. We even have a receptacle ready to plug in the boiler chemical pump which will only be energized when the boiler calls for water. In most cases the chemical pump will be furnished by your boiler chemical treatment people. The floor has catches and drains for spilled water if a leak should occur for any reason. The boiler will meet and exceed all state and national boiler codes and comes with a complete blow-down system. Both buildings are completely lighted and every valve and control has been placed to make it as easy as possible to operate and maintain. Please note the equipment and plumbing for grain treatment chemical is not included.
Energy requirements and specification: The double mill system will require electrical power to operate 300 h.p. a minimum of 400 amp service on 460 volt 3 phase 60 cycle power, as follows: 2- 50 X 4 dual drive hp roller mills, 10 hp on the boiler, 5 hp and 7.5 hp delivery and tempering augers, 2 hp on scalper, 5 hp on hydraulic system, 7.5 hp for flake transfer auger, lighting and miscellaneous electrical. Included are all the electrical control devises for these items using an industrial motor control load center as the heart of the system. The boiler will require at times, (high fire 75% of the time when running 2 mills) 13 million Btu input. Gas consumption with the one mill will be approximately 5 MCF per hour and related to flake produced will cost $1.95 per ton of flake corn when gas cost $5.20 per MCF = 1000 cubic ft. which equals 1,000,000 Btu of heat. The boiler will require natural gas to be provided at one to eight pounds of pressure and may require a separate regulator which is not included. The initial electrical hook-up will require a local electrician The double mill unit has a 300 hp and single mill unit a 150 hp William and Davis 2 pass boiler with digital electronic controller, turbulators, make-up water system, complete soft water system, all necessary high pressure steam piping using only schedule 80 piping with weld fittings including the transmission line from the boiler to the mill building which will be insulated and jacketed. The boiler installation will meet or exceed all national, state, and local codes pertaining to boilers. This is a complete steam flaking system and is automated as much as possible for ease of operation including automatic opening of rolls should they ever run out of grain. This system is designed to produce the very best flake grain product with the technology available today. Gearn will supply all necessary concrete blueprints and specification. The boiler will require water at 30 psi 40 gallon per minute, and a drain for the soft water regeneration, brine water, and blow down water. The boiler will require to be blown down several times each day. Included in the boiler system is a boiler blow down tank. The water from soft water regeneration and boiler blow down should be placed in lagoons or a leach field. A single Gearn 24" X 48" roller mill will produce between 12 to 16 tons of flaked corn per hour depending on grain condition and flake weight.
Further information: Package A. The compete mill package with one 24" X 48" Gearn mill in single building using a 1,000 bushel leg and scalper. B. The complete mill package with one 24" X 48" Gearn mill expandable to two mills *** C. The complete mill package with two 24" X 48" Gearn mills. D. The complete mill package with two 24" X 48" Gearn mills expandable to three mills with electrical switch gear. E. The complete mill package with three 24" X 48" Gearn mills
Package A. and B. have one 1,000 bushel scalper and one 1,000 bushel stainless steel leg included in the package. In Mill package (C.) the price includes a 3,000 bushel stainless steel leg for charging the steamchest, also a 3,000 bushel scalper and one 9" tube auger for feeding the scalper instead of the 1,000 leg and scalper also separate boiler building with 300 hp boiler. The (D.) package includes 400 H.P. boiler larger mill building and the additional electrical switch gear for the third mill.
* Requires cold weather package option ** Has one building with mill room, control room and boiler room, 150 hp boiler. *** Has separate boiler building a 300 hp boiler with space in mill building for second 24" X 48" mill.
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