New Bühler OLFC flaker combines longer roll life, lower vibration, and smarter operation

Flakers are used in oilseed processing plants to press cracked seeds, such as soybean, canola, and sunflower seeds, into thin flakes before oil extraction, a step that runs continuously. With each OLFC flaker processing up to 500 tonnes per day and plants operating several production lines with numerous flakers, equipment reliability is a key operational requirement. Unplanned downtime reduces throughput and disrupts production schedules. Flaking also plays an important role in oil extraction as the size, thickness, and thickness consistency of the flakers influence how efficiently oil can be extracted further in the process. 

Solid foundation

To address reliability under continuous operation, Bühler's engineering team, together with customers, identified components subject to the highest mechanical stress and reinforced them in the OLFC. 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 to the base frame. Together, these changes reduce machine vibration by up to 25% while creating a more robust platform for long-term operation. 

The newly launched OLFC also features larger rolls, with a diameter of 820 millimeters (mm) compared with the industry standard of 800 mm. Combined with an extended usable diameter, this increases roll service life by 150%, reducing replacement frequency and lowering the total cost of ownership.  

In addition, the OLFC comes with an upgraded hydraulic system that helps protect it from sudden pressure spikes, including those caused by foreign objects entering the equipment. This reduces the risk of unexpected stoppages and helps keep maintenance costs under control.

The OLFC uses a timing belt that transfers power more efficiently than conventional belt systems. As a result, the solution consumes up to 4% less energy than its predecessors. 

The maintenance benefits are also significant. An auxiliary drive rotates the rolls at low speed during grinding, allowing safer and more efficient roll service. This simplifies routine interventions 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. From the reinforced frame and reduced vibration to longer-lasting rolls and easier maintenance, we focused on creating a machine that delivers reliable performance throughout its lifecycle," said Lukas Spannagl, R&D Project Manager Value Nutrition at Bühler. 

Built to stay ahead

The OLFC integrates mechanical improvements with a completely redesigned automation system. A new touchscreen with clear, intuitive graphics gives operators a real-time view of the machine’s status. The simple interface reduces complexity and helps operators quickly find the information they need. An integrated sensor system provides real-time insights into machine performance. 

Operators can also consolidate data from multiple flakers to compare performance and identify maintenance before they become critical. Using Bühler Insights, the company’s digital platform for machine monitoring and analytics, they can monitor long-term trends and optimize maintenance planning. 

“To make operation of the machine as seamless as possible, we have adopted a more intuitive design language that operators inherently understand, making the system easier to learn and faster to master,” said Abdulqadir Abshir, Product Manager Value Nutrition at Bühler. “For that, we combined new sensors, meaningful data visualization, and customer feedback to make it easier to see what's happening in the process and take action.” 

As processors face growing labor shortages and a decline in experienced personnel, embedded process expertise can help operators make better decisions and maintain consistent performance.

Developed with customer feedback

The OLFC was developed in close collaboration with customers across major oilseed processing regions, including North America, Europe, and China. Customer feedback shaped multiple aspects of the machine, from usability and maintenance access to digital insights and sensor placement. Bühler validated the design through two prototype installations at soybean processing plants based in the United States. One of the units has been operating under real production conditions since October 2023. 

Following successful validation in commercial soybean processing plants, the OLFC is now available to customers worldwide.