Swiss technology group Bühler launched the OLFC, a new flaker system for processing oilseeds, with features aimed at helping processors maintain continuous production and reduce maintenance needs.
The OLFC processes cracked seeds like soybean, canola and sunflower into thin flakes before oil extraction. Each unit can handle up to 500 tonnes per day, and plants typically run several production lines with multiple flakers operating around the clock.
To improve reliability, Bühler’s engineering team worked with customers to identify components under the most mechanical stress and reinforce them. The changes include a strengthened base frame, cast components in the bearing unit, larger-diameter pulleys to reduce belt load, reinforced roll shafts and revised motor fixation. These modifications reduce machine vibration by up to 25% compared to earlier models.
The system features larger rolls with a diameter of 820 millimeters, compared with the industry standard of 800 mm. Combined with an extended usable diameter, this increases roll service life by 150%, cutting replacement frequency and lowering total cost of ownership.
An upgraded hydraulic system helps protect the equipment from sudden pressure spikes, including those caused by foreign objects entering the machine. This reduces the risk of unexpected stoppages and helps control maintenance costs.
The OLFC uses a timing belt that transfers power more efficiently than conventional belt systems, consuming up to 4% less energy than previous models.
For maintenance, an auxiliary drive rotates the rolls at low speed during grinding, allowing safer and more efficient roll service. This simplifies routine work and helps minimize downtime. Saving two hours can preserve around 41 tonnes of processing capacity per flaker.
“Every major design decision in OLFC was driven by one objective: helping customers maximize uptime,” said Lukas Spannagl, R&D project manager at Bühler.
The system includes a redesigned automation platform with a touchscreen that gives operators a real-time view of machine status. An integrated sensor system provides performance insights, and operators can consolidate data from multiple flakers to compare performance and identify maintenance needs before they become critical.
Using Bühler Insights, the company’s digital platform for machine monitoring and analytics, operators can track long-term trends and optimize maintenance planning.
Bühler developed the OLFC with customers across North America, Europe and China. The company validated the design through two prototype installations at U.S. soybean processing plants, with one unit operating under production conditions since October 2023.
