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A stone-removing machine, or stone separator, is an advanced equipment that helps to remove stones and foreign material from crops like pulses, oil seeds, grains, and cereals. Here's a brief overview of the different kinds of new destoner machines.
Traditional Airflow-based Destoner
This old-school destoner relies on a simple airflow principle. It uses a constant blast of air to push away stones while letting clean grain fall through. The stones are then collected in a bag or bin. While cheap and needing little upkeep, it may not catch all the stones, especially if they are a similar size to the grain.
Air Pressure Destoner
This one is a tad smarter. It uses air pressure and vibration to do the dirty work. Grain is fed onto a vibrating deck where air shoots upwards. Light things like straw and husks get blown away, while heavier items like stones stay put. The deck's moving and the air's flow are adjusted to suit what is being cleaned. These destoners are better at catching stubborn stones but need more fiddling to get them right.
Gravity Destoner
Gravity destoners take separation a step further by factoring in weight. Grains go onto a vibrating deck where heavy stones sink to the bottom due to their weight. The lighter grains then slide down the deck and get collected. These are effective and popular, but operators must still learn how to set them up and may require spares from time to time.
Combined Destoner and Separator
Machines that both separate and remove stones offer maximum efficiency. Materials first pass through a screening system to get rid of light debris. Then, the vibrating deck and airflow work on stones. Finally, a magnetic section catches any metal. These all-in-ones save time but have higher price tags and take up more space. Their complex design may also require regular maintenance.
Air Jet Destoner
The air jet destoner is more advanced than the basic air flow model. It uses compressed air to blow out impurities. A vibrating screen then sorts material based on weight. This design is compact, efficient, and energy-saving but needs compressed air to work.
Compressed Air Destoner
This machine uses compressed air rather than a blower. It shoots out a quick burst of air that dislodges light impurities and grains while stones remain stationary. Like the air jet model, this one also saves on electricity but requires access to an air compressor all the time.
Multi-channel Air Flow Destoner
Recent models use air through channels. The operator can adjust the air volume in each channel to clean different materials better. This method is effective, eco-friendly, and reduces air use, but it costs more than others.
Capacity:
The detonation capacity of a new destoner machine indicates how much product it can process in a given time. It is often expressed in tones or kilograms per hour.
Separation Methods:
Modern destoners often use a variety separation techniques, such as air current separation, vibrating screens, hydro separation, or sensor-based separation. Each method has its own advantages and is suited for different types of stones and products.
Product Types:
Different destoners are designed to handle different products. For example, grain destoners are specifically designed to process grains such as rice, wheat, millet, and others. Conversely, the stone fruit destoners may have different designs and mechanisms to handle fruits such as cherries, peaches, and plums.
Separation Accuracy:
The accuracy and efficiency of a destoner machine are determined by its ability to properly identify and separate stones from the desired product. This is often made possible through advanced sensors, detection algorithms, and separation mechanisms.
Operator Manual:
It is important to read and adhere to the operator manual provided by the manufacturer. The operator manual offers specific instructions and advice on machine maintenance, safety, operating techniques, and more.
Clean and Disinfect:
Regularly clean and disinfect the surfaces and components of the destoning machine to avoid cross-contamination and product quality issues.
Security Checks:
Before operating the duster machine, check whether relevant accessories are secure, electrical circuits are normal, and operating levers are flexible, thereby ensuring safe operation.
Lubrication:
Do routine lubrication maintenance according to the operator handbook, thereby ensuring the equipment's reliable operation and service life.
Training for Operators:
The machine operator should be trained and understand the correct operation and maintenance methods of the new destoner, ensuring proper use and care.
Grain processing plants:
Grain processing plants utilize new destoner machines as an integral part of their grain cleaning process. These machines efficiently remove stones and other heavy impurities from the grain, ensuring that only clean and quality grain is processed into various food products. The use of new destoner machines not only improves the quality of the end products but also enhances the overall efficiency of grain processing plants.
Baking industry:
The baking industry heavily relies on destoner machines to ensure the quality of flour and other grain-derived ingredients. These machines effectively remove stones and other unwanted contaminants from grains, preventing damage to milling equipment and maintaining product integrity. By incorporating destoner machines into their operations, the baking industry can produce high-quality flour and minimize the risk of foreign objects in their baked goods, thereby safeguarding the satisfaction and safety of their customers.
Cashew processing:
In cashew processing, destoner machines play a crucial role in ensuring the quality and purity of cashew nuts. These machines effectively remove stones and other foreign materials that may be mixed with the cashews during harvesting and processing. By using destoner machines, cashew processing facilities can maintain the integrity of their product, minimize the risk of consumer complaints, and uphold industry standards.
Rice mill factories:
Rice mill factories heavily rely on destoner machines to ensure the quality of processed rice. These machines efficiently remove stones, pebbles, and other heavy impurities that may be mixed with the paddy or raw rice. By incorporating destoner machines into their production line, rice mill factories can protect their milling equipment, enhance the purity of their final product, and meet the stringent quality demands of consumers and food safety regulations.
Nuts and dried fruit packaging:
When it comes to packaging nuts and dried fruits, stone removal is of utmost importance. Destoner machines play a crucial role in this process by effectively eliminating stones and foreign objects that may be mixed with the nuts and dried fruits. Whether it's peanuts, walnuts, cashews, or dried fruit like raisins, dates, or dried berries, destoner machines ensure that only high-quality products free from any unwanted contaminants are packaged. This not only enhances the quality of the final product but also protects consumers from any unpleasant surprises.
Vegetable processing:
In vegetable processing, new destoner machines have become indispensable equipment for ensuring the quality and safety of processed vegetables. Whether it's potatoes, carrots, beets, or other root vegetables, these machines effectively remove stones and sand before the vegetables undergo further processing, such as cutting, cooking, or freezing. By incorporating new destoner machines into the vegetable processing workflow, manufacturers can minimize the risk of foreign objects in their final products, protect processing equipment, and meet stringent food safety standards.
Use the following checklist when sourcing stone remover machines:
Production capacity:
Understand the amount of product the machine can handle in one operation to see if it meets business needs.
Sort-out accuracy:
Select devices known for accurately identifying and removing stones without wasting quality produce.
Ease of use:
Choose a machine with a user-friendly interface so it can be quickly operated and mastered by staff with minimal training time.
Maintenance requirements:
Consider the needed upkeep and choose a destoner that does not demand constant professional maintenance to avoid high long-term costs.
Durability and build quality:
Invest in a stone remover built to last from robust materials with a design that can withstand regular, intensive use in demanding commercial environments.
Compatibility with existing setup:
Ensure the new machine will integrate well within the current production line to avoid the cost of major facility upgrades.
Energy efficiency:
Opt for models that use less electricity, as these impact the overall operating expenses by lowering utility bills.
Spare parts availability:
Select popular brands where crucial replacement components are readily available to prevent prolonged machine downtime.
Initial cost and total lifetime expense:
Understand the purchase price and calculate the total expense over the machine’s life, including energy, repairs, and depreciation.
Q1: Which crops need a destoner machine?
A1: Several crops, including millet, rice, wheat, barley, mustard, and other pulses and spices, require the use of a grain destoner. Crops that contain numerous organic and stone contaminants are pumped through a series of vibrating sieves with air jets blowing through them. The specific weight and size allowed the stones to fall outside of the collection area while the organic material was allowed to pass through the exit.
Q2: Is a grain destoner the same as a grain separator?
A2: No, while some operations may call a grain destoner a grain separator, the two are fundamentally different. A grain separator uses size and shape to separate out organic material, such as grains, whereas a grain destoner works upon differing specific weights to remove stones. Air flow and screen vibratory settings are the primary differences between the two machines.
Q3: Is a grain or stone separator necessary in the milling process?
A3: Yes. Without a grain destoner machine, stones could enter the milling process and cause significant damage to the machines and milling equipment. Such damage could amount to several millions, and production would come to a halt to try to assess the situation. Therefore, destoners and grain separators are critical components of the pre-milling processes.
Q4: What is the principle behind grain destoners?
A4: Grain destoners work upon the principles of weight and size. As mentioned earlier, the specific weight and size of stones or any other unwanted material differs from that of grains of cereal. Using the vibration and air flow technique, grains with lighter specific weights are allowed to pass through, while stones and other contaminants with heavier specific weights are removed through the system.
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