Seed Conditioning Presentation for Agronomy 338

15 Pages·2017·4.9 MB·English

© Copyright ISU Seed Science Center, duplication or distribution without written permission is prohibited
Review Topics
Seed Conditioning Technology
 Conditioning Applications
(Part 1 of 2)
 Harvest & Storage Issues
Agronomy / Horticulture 338
 Material Handling Basics
Seed Science and Technology  Separation Methods
Fall 2017  Pre-cleaning / Preparation
 Cleaning & Sizing
Alan Gaul  Upgrading Equipment*
 Treating & Packaging*
Seed Conditioning Specialist
 Definitions & Quality Tests
515-294-4011
 Pending Lab Discussions
[email protected]
* more detail in 2ndpresentation
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Why Condition Seed? Additional Conditioning Issues
•Harvest
•Seed Extraction
•Threshing
•Drying
Soybeans Adzuki Beans •Specialized Treatments
• Threshing & Moisture Removal
• Weed Seed & Foreign Material
• Diseased & Immature Seed
• Improve Appearance, Uniformity
Seed Corn • Add Protective Coatings
Seed Science Center Seed Science Center •Images Courtesy of Prairie Habitat and Seed Processing Holland
Production Facilities General Conditioning Flow Diagram
Harvest
Separating
Receiving Pre-Cleaning Cleaning
& Upgrading
Bulk Storage Treating & Bagging
Objectives:
•Remove All Contamination
Storage Shipping
•Minimize Seed Loss
•Remove Low Quality Seed
•Maximize Capacity Grower
Midwestern seed plants are •Minimize Labor Required
gradually becoming larger, more
complex industrial facilities
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Basic Soybean Flow Diagram Typical Flow for Seed Corn
Harvest Harvest
Color Sorter
Color Sorter Gravity
Ear Corn Plant light/dark
Pre-Cleaner Spiral/Belt Separator(s)
Width Sizer
Separator Light
Dark Pre-Cleaner broken light
Bulk oblong Seed Treater Thickness Thickness
Sizer Sizer Seed Treater
Storage Bulk
Storage
Indent Cylinder Sizers
Air Screen Gravity Bagging Line short Bagging Line
Cleaner Separator Air Screen Sized Corn Bins
trash light Finished Seed
Finished Seed Cleaner trash
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Harvest & Storage Concerns Ear Corn Harvest & Receiving
Picking Receiving
Limit Mechanical Damage Maintain Quality in Storage
•Reduce cylinder or rotor speed •Limit incoming moisture Husking Sorting Drying
•Avoid running at partial capacity •Pre-clean seed if possible
•Level bin and aerate properly • Wet ear corn is harvested & transported to plant
Avoid Varietal Contamination • Husks are removed and “off types” sorted manually
•Careful drying may be needed
•Extensive cleaning is required to reach safe moisture levels • Husked corn is then dried prior to shelling
Shelling
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Ear Corn Harvest Issues Husk & Sort Facilities
Truck Unloading
ADVANTAGES
Distribution Conveyor
–Early Harvest of High Moisture Corn
–Field Loss Reduction (Fungi, Insects, Weather) Feeder Feeder Feeder
–Potential for Double Crop in Warm Climates
Shelled Corn
–Additional Time for Post Season Operations
Husker Husker Husker
–Visual Inspection for Quality Control
Husks
DISADVANTAGES Sorting Sorting Sorting
–High Initial Investment for Ear Corn Facilities Belt(s) Belt(s) Belt(s)
–High Labor Costs for Sorting & Handling Rogue Discard Husk & Discard
Rerun
–High Fuel Cost for Drying Sorted Corn Ear Corn Dryer
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Ear Corn Dryer Type Diagrams Ear Corn Dryer Types
Single Pass Double Pass Single Pass Double Pass
Single Pass Reversing Based on Airflow Pattern Single Pass Reversing Single Pass
•Bin Qty for Series Airflow • Lowest cost per bushel
• Small lots –shallow depth limits
•Airflow Direction Changes
Single Pass Reversing
Key Differences:
• Modular independent bins
•Management Complexity • Relatively simple management
•Airflow Volume Required Double Pass
•Energy Efficiency • Energy Efficiency
• More difficult to manage
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Production Ear Corn Shellers Automated Shelling Lines
• Axial Flow Configurations Typically Found at Larger
Sorting
Seed Research Operations
• Round Bar or Perforated Cage
• Rotor Speed affects Seed Damage Sheller
• MUSTmaintain Product in Hopper
Cleaner
Conical Cage
Color
Sorter
Treater
• Automated batch operation
• Pneumatic seed transfer
Packeting
Round Bar Cage Perforated Cage, Integral Cob Blower • Typically 12-20 ears per batch
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Material Handling Systems Mechanical Damage during Conditioning
•Elevator Legs
•Belt Conveyors Auger
Damage
•Drag Flight Conveyors
Moisture
•Vibratory Conveyors Effect
•Pneumatic Conveyors
•Gravity Spouts and Letdowns
Germination vsSequence for 2 Moisture Levels
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Mobile Conveying Equipment Conventional & Continuous Cup Legs
Portable Belt Conveyor • High Capacity • Flexible Layout
• Compact • Multiple Discharge
• Easily Enclosed • Minimal Damage
• Lower Cost • Self Cleaning
• Vertical Lift Only • Limited Capacity
Screw Conveyor
• Some Damage • Maintenance
• Boot Cleanout • Higher Cost
•Typically for stationary
vertical lift applications
•Trend for continuous
cup leg designs for high
value or fragile seeds
Pneumatic Conveyor Conventional Continuous Cup
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Vibratory Feeders & Conveyors Letdown Devices
Variable Feeder Letdown Ladder Letdown Ladder Spiral Letdown
• Commonly Used
• Easily Fabricated
• Modular Design
• Relatively Compact
• Can be Rubber Lined
• Multiple Small Impacts
Spiral Letdown
Receiving Conveyor • Less Common
Transfer Conveyor • Eliminates Impacts
• More Difficult to Build
• Self Cleaning • Horizontal Only
• Harder to Rubber Line
• Multiple Outlets • Limited Distance
• Need to Match Spiral
• Moderate Cost • Vibration Issues Slope to Seed Type
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Mechanical Damage Detection Minimizing Mechanical Seed Damage
Unloading
Reduce seed velocity
• Minimize drop height in spouts or transfer points
Receiving Leg Leg 1
• Use lowest RPM needed to provide required capacity
• Use a larger conveyor running at lower speed
Belt Conveyor Belt 1
• Use the lowest possible incline angle
Reduce impact, abrasion, crushing or shearing actions
Air Screen
Cleaner • Eliminate pinch points and sharp edges
Cleaner Screen Shaker • “Run in” conveyor to polish rough surfaces prior to use
Percent Broken Seed • Run most conveyors at (or near) Full Capacity
Cleaner Leg Leg 2 • Soybean -% Splits (10/64” Slot) • Consider rubber or plastic product contact surfaces
• Corn -% BCFM (12/64” Round)
• Modify conveyors if needed to avoid crushing seed
Seed Coat Damage
Inclined Spout Spout 1 Take extra precautions at cold operating temperatures
• Soybean –Soak Test
• Corn –Fast Green Dye
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Dry Granular Separation Principles Seed Cleaning - Physical Properties
 Separation based on Differences in – Aerodynamic Properties (terminal velocity): Aspirator
various Physical Properties
– Seed Size & Shape: Air Screen Cleaner
 Common principles used:
Aerodynamics/Terminal Velocity – Dimensional Separation: Length, Width, & Thickness Sizers
Approximate Seed Size – Rolling Resistance: Spiral and Belt Separators
Seed Dimensions (L-W-T) – Specific Gravity (Density): Gravity Separator & Destoner
Seed Shape (Rolling Resistance)
– Color (UV, visible spectrum, NIR): Color Separator
Product Density
– Surface Texture: Velvet Roll, Vibratory, Magnetic Separator
Color Differential
 Most“real world” applications – Affinity for Liquids: Buckhorn Separator
require multiple techniques – Electrical Characteristics: Electrostatic Separator
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Types of Contamination Tools of the Trade (1/4)
• Foreign Material -Plant parts, stones, dirt, bugs, etc.
Aspirator
• Other Crop Seed –“Alternative” crops  Vertical or inclined air column
 Usage: Pre-cleaning or removal of
• Weed Seed-Other undesirable non-crop seeds light contaminants
• Mechanical Damage –Chipped or broken seed Air-Screen Cleaner
 One or two aspiration columns
• Varietal -Other varieties of the intended crop  Multiple perforated screens
 Usage: Removal of light
• Physiological -Physical or biochemical issues
contaminants, undersized, and
oversized material
• Pathological -Seed diseases and/or insect damage
•LMC Corporation and WestrupUSA
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Aspirator Examples Scalping Aspirators Inlet
Scalperator
Cross Sections Outlets
Air
•Combined Scalping Reel and
Conical (Spout) Multiple Pass Cascade Aspirator Aspiration in same machine
•Many different aspirator configurations are available •Simultaneous oversize and
light material removal
•Primary difference include number of air passes
through seed, length and slope of aspiration column •Common for high capacity
removal of trash from seed
Pneumatic Column •Designs are typically adapted for specific applications
Scalping Aspirator
•Images courtesy of LMC, Forsberg, Kice, and SeedTechSystems
Seed Science Center Seed Science Center •Courtesy of Carter-Day Int’l & WestrupUSA
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Size, Shape, & Aerodynamics -Air Screen Cleaner Example - Air Screen Cleaner Results
Screen Example Upper Air Oversize Undersize Lower Air Clean Seed
s
n
a
e
b
y
o
S
n
or
C
d
Vaughn & DeLouche, 1968 e
e
S
•Air and Sieve Operations
•Removes FM, Light, Broken, x
a
Undersize, & Oversize Seed Fl
Air-Screen Cleaner
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Screen Perforations Screen Selection
•Hole geometry & •CIMMYT Slide Archive •Achieves maximum removal of
size determined by
foreign material and minimum
application
removal of good product
•Layout affects •Removal of foreign material by
capacity and screen Round Parallel Slot cleaner improves effectiveness of
efficiency other downstream processes
•Size specified in
Mechanical screen
English or Metric shaking equipment
Wire Mesh Cross Slot can be used to
•Multiple screen provide more
sizes are typically consistent results
used for most seed and permit shaking
tall screen stacks
applications
Triangular Herringbone Slot
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Screening / Sizing Terminology Screening / Sizing Efficiency
Screen Input Screen Input
Oversize Material Oversize Material
(“overs”) (“overs”)
Undersize Material Undersize Material
(“thrus”) (“thrus”)
Screening Terminology: Sifting Efficiency (undersize removal)
•“Scalping” –Removal of Oversize Material from Product •Percent of Total Undersize Material passing “thru” the screen
•Screen Capacity is limited by desired sifting efficiency
•“Sifting” –Removal of Undersize Material from Product
•“Sizing” –Dividing the Product into two Size Ranges Scalping Efficiency (oversize removal):
•Percent of Total Oversize Material passing “over” the screen
•“Efficiency” is based on the desired operation type
•Scalping Efficiency may be close to 100% for spherical seed
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Tools of the Trade (2/4) Seed Size Definitions
Indent Cylinder or Disc Separator
Same thickness, different width
 Indented pockets sized for length
separation Width
 Usage: Separation of long from
short material (ex: wheat/oats)
Same width, different thickness
Precision Sizer
 Rotary cylinders with Round or Thickness
Slotted perforated holes
 Usage: Sizing or removal of Same width & thickness but
contaminants based on Width or
Thickness different length
Length
•Carter-Day Int’l and Oliver Manufacturing Co.
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Length Grading – Indent & Disc Separator Laboratory Indent Cylinders
Indent Cylinder Disc Separator
• Traditionally operated in “batch” mode
Removes Short or • Newer machines capable of either batch or continuous flow
Long Seed from • Used for Cylinder Selection and Cleaning Small Lots
Primary Fraction
• Adjustments include Size, Speed, & Trough Position
•Images Courtesy of WestrupUSA, Inc.
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Disc Separator De-Sticking Sunflowers
V Pockets (Spherical)
R Pockets (Cylindrical)
•Stems and sticks are hard to
remove using conventional
perforated screens
•“V” (“Vetch”), “V”+Width (mm), V2.5 thru V6.5 Square Pockets (Desticking) •Lifting sunflowers from sticks can
•“R” (“Rice”), “R”+Width (mm), R 3.5 thru R6 be accomplished using either a
•Square (desticking), Letter Designation disk or indent cylinder separator
•K, L, M, AC, EE, J, A, MM, B, RR-SS, DD, AE-AD, SS-DD
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Width and Thickness Sizer Sizing Flow Diagram (4 Sizes + Discard)
Input From Cleaner
Over 19R Thru
Over 15R Thru
Discard
Width –Round Hole Thickness -Slotted 12S Over 11.5S Over
•Typical sizing stack uses multiple
machines to create desired sizes
Thru Thru •Cylinder quantity is based on flow
rate at each machine location
LF LR SF SR
•Cylinder capacity depends on %
“thrus” and desired efficiency
Vaughn & DeLouche, 1968
•Oliver Manufacturing and Carter-Day International
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Sizing Cylinder Selection Sizing Cylinder Capacity
Cylinder Selection Factors:
•Fractional quality evaluation Round Hole
•Percent breakout by fraction
Round Slotted
•Size range limits (plantability) Slotted Hole
•Marketing requirements
Large Medium Small
Oversize Undersize
Discard Discard
•Capacity is typically rated at 95% efficiency (or higher)
•Cylinder capacity is higher for round hole configurations
Lab Sizer •Cylinder capacity increases with higher percentage of thrus
•Adapted from Carter-Day Data (1995)
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Flat Screen Sizing (modular cleaners) Tools of the Trade (3/4)
Spiral Separator
 Inclined helical flights sloped to
match rolling speed
 Usage: Separation of spherical
from non-spherical products
Belt (roll) Separator
•Alternate to cylinder sizerson seed corn applications  Inclined moving belts
•Limited evidence of reduced mechanical damage, possibly greater  Usage: More precise separation
for round seed (Popp, 2003) based on differences in rolling
•Sizing efficiency is typically lower than for cylinders speed of various products
•Capacity is less than equivalent air screen cleaner
•Image Courtesy of WestrupUSA, Inc. •Profile Industries, Q-Sage, and Harada Sangyo
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Shriveled or Oblong Seed Causes Static Spiral Examples
•Immature Seed •Frost Damage •Drought
•Diseased Seed •Field Conditions •Other Factors
•Images courtesy of Profile Industries
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Rotary Spiral Examples Belt Separator
•Original “Draper Belt” design –single slope
•Later modified to use dual belt slope
•Provides multiple fractions, fewer collisions
Single Core Multiple (4) Cores Core Replacement •Multiple belts stacked to provide more capacity
•Images courtesy of Profile Industries
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Belt Separator Samples Tools of the Trade (4/4)
Flat Oblong
Gravity Separator
 Reciprocating inclined fluidized
bed to “float” light from heavy
Shriveled Round  Usage: Density separation of light
weight or heavy product
Flat
Color Sorter
 Optical separation based on
Round differences in color or intensity
 Usage: Removal of dark and/or
light discolored material
Single Belt
•Oliver Manufacturing and SatakeUSA
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Fluidized Bed Density Separation Optical Detection & Separation
Destoner
•Two Density Fractions
•Removes Heavy Material
Accepts
Gravity Table
Rejects
Gravity Separator
Color Sorting Equipment
•Continuous Density Range
•Provides Two Color Fractions
•Multiple Fractions Possible
•Removes Light or Dark Material
Destoner •Removes Low Density Seed
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Treating & Coating Seed Treating Equipment
Seed Coating
Continuous Flow
Used to Apply Treatment or Coatings:
•Correct Proportion of Seed & Chemical
• Provide Pathogen Protection
• Improve Planter Performance •Acceptable Appearance & Product Flow
• Better Product Appearance •Proper Application Rate
Seed Pelleting • Increase Seed Size (Pelleting) Automatic Batch •Uniform Seed Coverage
•Seed Images Courtesy of Seed Processing Holland •Images courtesy of Gustafson Equipment (Bayer)
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Packaging Storage and Shipment
Bulk Bag Filling
Package Type Factors:
•Market Requirements Warehouse Considerations:
•Volumetric Issues • Space Requirements
•Desired Automation • Material Handling Facilities
•Downstream Handling • Possible Climate Control
Conventional Bag Filling Equipment Availability • Traffic Control and Security
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