by Blake SandnesConsistent performance in a roller mill comes down to precision, but that’s easier said than done—especially when multiple operators adjust the settings. Inconsistent roll adjustments among operators can cause variations in grind size, resulting in out-of-spec products and reduced efficiency.
For industries like livestock feed production, distilling, and soybean milling, minor inconsistencies can lead to reduced quality, product rejections, and even loss of customers. Roll Gap Control and AccuGap® address these challenges with advanced roller mill controls, improving precision throughout the milling process.
But what exactly do these systems do, and how do they differ? Let’s break it down in simple terms.
What Is Roll Gap Control?
Roll Gap Control optimizes grinding precision by automatically adjusting the space between rollers, ensuring consistent results and streamlined operations. While roller speed, feed rate, and grain hardness all affect grind size, the roll gap has the most impact. Adjusting this gap manually can be time-consuming, inconsistent, and prone to operator error. With Roll Gap Control, operators select a preset recipe, and the automatic roller mill adjusts the gap by itself—saving time and reducing errors.
Key Benefits of Roll Gap Control:
- Faster adjustments: Change grind sizes quickly with preset selections.
- Operator consistency: The settings remain the same no matter who’s running the machine.
- Remote operation: Ideal for mills where the roller mill isn’t near the control room.
- Better efficiency: Reduce downtime and keep production flowing smoothly.
If your operation requires frequent grind size changes or multiple operators handle the feed roller mill, Roll Gap Control ensures that each setting is precise, repeatable, and efficient.
What Is AccuGap®?
AccuGap® takes calibration further, keeping the rolls parallel and properly aligned. The gap in a roller mill is often set within thousandths of an inch, meaning even the smallest misalignment can impact performance. AccuGap® eliminates the guesswork by providing a precise calibration system, ensuring that the rolls are zeroed and aligned every time.
Why AccuGap® Matters:
- Eliminates roll misalignment: Prevents uneven grinding and product inconsistency.
- Removes manual calibration errors: No more relying on “eyeballing” or guesswork.
- Ensures repeatable precision: Consistently accurate calibration every time.
For mills that demand the highest level of accuracy, AccuGap® is a major improvement. It provides a reliable way to maintain roll alignment, reducing variations and improving the overall consistency of your automatic mill.
Applying Roll Gap Control and AccuGap® Across Industries
No matter the industry, Roll Gap Control, and AccuGap® work together to deliver consistent, efficient milling. Use only one, and you risk inconsistencies creeping into your process. Use them together, and you get a finely tuned automatic roller mill system that keeps operations smooth and product quality high.
Here’s how these roller mill controls work together in different industries:
Livestock Feed Mills (High-Volume, Multiple Grind Sizes)
Feed mills frequently switch between grind sizes to meet the nutritional needs of various animals. For example, swine feed requires finer particles, while poultry feed can be coarser.
How They Work Together:
- AccuGap® keeps rollers perfectly aligned, preventing uneven particle sizes that could impact livestock digestion and feed efficiency.
- Roll Gap Control automates grind size adjustments, ensuring smooth transitions between feed types.
Distilling (Consistent Particle Size for Extraction)
Distillers require precise particle sizes to maximize starch extraction and alcohol yield. If the grain is milled too coarsely, extraction is inefficient; if too fine, lautering issues arise.
How They Work Together:
- AccuGap® ensures that rollers stay aligned over long production runs, maintaining uniform particle size for consistent extraction.
- Roll Gap Control allows for quick adjustments between grain types and moisture levels, ensuring optimal grind consistency.
Flour & Grain Milling (Fine-Tuned Precision & Repeatability)
The flour milling industry demands highly consistent, fine particle sizes to meet baking and food processing standards. Even slight inconsistencies can alter hydration, texture, and baking performance.
How They Work Together:
- AccuGap® locks in perfect roller alignment, maintaining uniform flour consistency.
- Roll Gap Control enables fast, precise recipe changes, keeping production efficient without sacrificing quality.
Industrial & Specialty Milling (Soybean, BioChar, etc.)
Specialty milling operations process various materials, each requiring different grind settings to optimize performance and product consistency.
How They Work Together:
- AccuGap® keeps rollers perfectly aligned during long production runs, preventing performance drift and ensuring long-term efficiency.
- Roll Gap Control automates grind size adjustment for raw materials without manual recalibration.
Take the Next Step in Roller Mill Optimization
Precision grinding requires the right roller mill controls. Whether you’re looking for faster grind size adjustments with Roll Gap Control or superior calibration with AccuGap®, RMS Roller-Grinder has the technology to enhance your operation. Upgrade your system today to achieve repeatable accuracy, efficiency, and consistency in every batch.
Contact RMS Roller-Grinder to see how these controls can improve your mill!
