Enhancing Grain Processing Efficiency: The Power of Tank Insulation

In the detailed journey from farm to table, grain processing plays a pivotal role in transforming raw grains into the diverse array of food products we, and our animals, enjoy daily.

In this article, we'll explore the importance of proper tank insulation in grain processing, a crucial aspect often overlooked, and how it can significantly impact efficiency and product quality. As well as take a deeper look into a case study MC&I, Inc. performed at Grain Processing Corporation in Washington, IN.

Understanding Grain Processing

Grain processing is a vital step in the journey from farm to table, especially when it comes to agricultural commodities like grains. The objective of this practice is to refine raw grains, making them suitable for various end uses, primarily as food ingredients.

This intricate process unfolds in several phases, each contributing to the enhancement of grain quality and suitability for human consumption.

The initial stage, known as primary processing, involves several essential steps.

First, grains undergo thorough cleaning to remove any impurities and foreign substances, ensuring they are as pure as possible. At the same time, grains are sorted and graded into different quality categories.

Removing the protective outer layers, called husks or hulls, is another critical part of primary processing. These husks are not fit for human consumption and must be taken off to make the grains ready for further processing.

Now, let's dive into the husk removal process a bit more. This step can be done using either traditional or advanced mechanical methods.

After husk removal, the grains go through a carefully controlled drying process to reach the right moisture levels, preserving their quality and preventing spoilage. Once they are dried, the grains are packaged meticulously using appropriate materials to keep them safe during storage in warehouses or storage facilities.

During storage, great care is taken to protect the grains from potential harm. Factors like pests, moisture, temperature changes, and environmental conditions are managed rigorously. Advanced storage practices may involve the use of silos, which can hold large quantities, often exceeding 100 tons, of grains.

Wet Milling VS Dry Milling

Now that we've got a grasp of the basics in grain processing, let's take a closer look at the differences between wet milling and dry milling.

In dry milling, materials are typically reduced in size through direct contact between particles, while wet milling involves immersing the material in a liquid and using solid grinding elements to achieve the desired reduction in size.

Both methods can break down products, but let's start by exploring the more complex process of wet milling.

Wet Milling

Wet milling, often known as wet grinding, is a process where particles suspended in a liquid slurry are dispersed by either shearing or crushing actions.

After the milling process is complete, these particles are ready to be used or can undergo drying and separation to be integrated into other products.

It's important to note that wet milling, due to the addition of a liquid, is a more complex procedure than dry milling. However, this complexity offers the advantage of finely reducing a product into smaller particles.

This capability allows for the production of a wider range of byproducts and can result in improved physical properties in the final product.

Dry Milling

On the other hand, dry milling doesn't involve any liquid component and is primarily used for reducing the particle size of dry materials like powders and granules.

It is also employed for the purpose of declumping bulk materials.

While dry milling is a simpler process, which often makes it the initial choice, when the goal is achieving extremely small particles, wet milling emerges as the superior and most efficient approach.

The Importance of Tank Insulation in Grain Processing

Insulation takes on a crucial role in the context of these applications. Its importance lies in its ability to control several vital aspects of the process.

Firstly, it helps manage condensation effectively. This control is essential because it helps prevent the formation of mold and mildew, which can be detrimental to the stored products.

Insulation also acts as a shield against freezing. When products are kept in tanks or silos, insulation prevents them from freezing, ensuring that they remain in a uniform state when they are unloaded.

Furthermore, insulation contributes significantly to cost savings. By conserving energy needed for heating or cooling the stored products, it helps reduce monthly energy costs, which is a practical benefit for any operation.

Additionally, insulation safeguards the stored products from extreme temperature variations. It prevents them from freezing or becoming excessively heated, particularly from the sun's radiation. This temperature regulation is crucial, especially when dealing with various dry bulk products stored in these facilities.

MC&I, Inc. was the natural choice for the Grain Processing Corp. Corn Storage Tank project, given our deep understanding of the critical role that proper tank insulation plays in industrial processes.

The Case Study

In this case study, we explore how MC&I, Inc. implemented the RIDGLOK? Vertical Standing Seam Panel Insulation System on a crucial storage tank for the Grain Processing Corporation (GPC) in Washington, IN.

This project aimed to optimize corn storage for GPC, a company specializing in corn-based products with diverse industrial applications.

The Role of GPC and Its Storage Needs:

GPC's product range encompasses maltodextrins, corn syrup solids, starches, dietary fiber for various industries, ethyl alcohol for beverages and industries, starches for paper, corrugated boxes, textiles, and wallboards, as well as crude corn oil and corn germ, along with ingredients for animal and pet nutrition.

To meet these multifaceted demands, an efficient storage solution was essential.

The Wet-Milling Process:

The tank in question served a critical purpose: holding corn for the wet-milling process.?

As we mentioned earlier in this article, during the wet milling process corn kernels are meticulously separated into their basic parts, which are then further refined to produce a wide range of valuable products.

The quality and integrity of stored corn are paramount for this process.

Project Specifications:

The storage tank itself was a substantial structure, boasting a 22-foot diameter and standing at an impressive height of 36 feet. The project, despite facing uncontrollable spring weather conditions and tight accessibility, was successfully completed in April 2015.

RIDGLOK? Insulated Panel System:

The heart of this project was the RIDGLOK? Insulated Panel System, a meticulously designed solution. It featured 0.024 stucco-embossed aluminum metal jacketing in a grey finish.

This was expertly laminated to a 1.5-inch polyisocyanurate insulation board, boasting an impressive R-value of 9.6. The system was seamlessly integrated into an external rafter roof system.

The Impact of The? RIDGLOK? Insulation System:

The RIDGLOK? Insulation System played a pivotal role by significantly reducing temperature differences within the tank.

This control over temperature helped manage condensation effectively and enhanced overall process control. Furthermore, it contributed to a reduction in routine maintenance while preventing energy waste, ultimately leading to lower fuel costs.

Client Feedback:

After the completion of the project, the Division Engineer at GPC expressed high praise. Notably, they commended the safety awareness of the insulating crew and the exceptional quality of the RIDGLOK Insulation System.

The Grain Processing Corp Project demonstrates MC&I, Inc.'s expertise in providing innovative solutions to enhance the efficiency and functionality of storage tanks.

The RIDGLOK? Insulation System's advantages, including improved thermal control and cost savings, make it a valuable asset for various industries, ensuring the integrity of stored products and optimizing production processes.

Don't hesitate to connect with us to explore how MC&I, Inc. can elevate your operations and contribute to your success. Together, we can create a more efficient, sustainable, and reliable future for your industry.