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EMPRAL Mills

The largest mill in the world

Maior Moenda

Milling capacity
1730 TCH (7,0 rpm)*
41.600 TCD e 7.700.000 TCS*
In just a single line extraction
*Fiber% cane of 13% and 185 days of harvest

The largest mill in the worl
1570 x 2650 mm (61,8" x 104,3")

In early 2014, EMPRAL will deliver two units of the largest mill of the world in size and milling capacity.

For 37 years EMPRAL Piracicaba researches and developstechnologies for milling of cane sugar, and for 23 years licenses these technologies.


The EMPRAL, sales leader since 2008, is specialized in offering projects for high milling capacity, maximum performance and low maintenance.

Standard Line

Standard Line

Mills MeasuresCapacity (TCH)
(mm)(pol)3,0 rpm6,5 rpm8,0 rpm
900x140035,43"x55,12"121263323
1000x170039,37"x66,93"184400492
1075x200042,32"x78,74"254550677
1175x220046,26"x86,61"336728896
1250x230049,21"x90,55"4008671067
1350x230053,15"x90,55"49110641309
1375x240054,14"x94,49"51011051360
1450x250057,08"x98,42"59412871584
1570x265061,80"x104,3"74316101982
Considered data for calculation

Capabilities as 1st mill, with the following data:
Fiber: 13%
Groove height: 62mm
Capacity as 2nd or other mills - multiply by 1.42.

Diffuser Line

Diffuser Line

The dryers Mills EMPRAL its mechanical design and its adjusting area adapter for drying the bagasse coming from diffuser.

Working pressures diffuser line: 27.5 to 30.0 tf/dm².

Mills MeasuresCapacity (TCH)
(mm)(pol)3,0 rpm4,0 rpm
1000x180039.37"x70.86"203270
1100x210043.31"x82.67"304405
1200x220047,24"x86,61"364485
1250x230049,21"x90,55"413550
1400x230055,11"x90,55"525700
1450x250057.08"x98.42"611815
Considered data for calculation

Capacities as dryer mill, preceded or not by dewatering mill:
Fiber: 13%
Groove height: 42mm.

BR Mills Line

BR Mills Line (Only for Exports)

BR Mills line was developed specially for export; its mechanical design and construction quality are the same as in the standard line, as well as the materials applied and optional .

Mills MeasuresCapacity (TCH) SHP
(mm)
exact
(pol)
nominal
5,0 rpm6,5 rpmSHP of work
tf/dm²
940x167637"x66"290370>25,0
990x198139"x78"380490>25,0
1070x213442"x84"485630>25,0
1170x228646"x90"630810>25,0
1320x254052"x100"9001170>25,0
Considered data for calculation

Capabilities as 1st mill, with the following data:
Fiber: 15%
Groove height: 62mm
Capacity as 2nd or other mills - multiply by 1,40.

NOTE: For other values ​​of fiber%cane, please contact us./p>

Cane Energy Line

Cane Energy Linea

The EMPRAL Piracicaba developed a special line for high fiber% cane sugar (20% -30%). Its mechanical design and its adjusting area already consider the ideal adjusting and pressures to work with high fiber (> 20%).

For more information, please contact us.

Bearings

Mancais das Moendas
EMPRAL Mills Bearings

EMPRAL Mills Bearings are dimensioned accurately and machined with high precision numerical control machines, eliminating the need of adjustment that enables the interchangeability between the bearings.

Top Bearings:

In the top bearings, the EMPRAL mills have innovated using the solid lubrication (graphite) between the bearing and the housing. Today, it innovates using Vesconite, self-lubricant material with the characteristics such as: long life, zero of dilatation, high strength to loads and chemical wears.

Heads

Cabeçote
Heads

Specially designed to support high pressures, the hydraulic heads are fixed through tapered keys , eliminating gaps, therefore making easy the vertical removing and allowing a quick maintenance. They have a piston coated of high stiffness ceramic material, eliminating wears and risks.

The head internal body is machined in high precision numerical control machine where the seal rings shall be placed.

Between the piston and the bearing housing, there is socket joints system transmitting the hydraulic load to the shafts, eliminating lateral loads.

Seal

vedação
Seal

In order to solve the problem of shafts and bearings premature wear, EMPRAL has developed special seals. The special seals are composed of rubber retainers, a series of stainless steel rings and a rubber bellows coated with Teflon thus absorbing the gap in the assembly.

Flange – Manufactured in carbon steel plate ASTM A-36, machined in numerical control machine allows a correct internal face angulation. The flange drilling is machined with a proper design. The fastening screws are of a special alloy for greater strength. The flange internal face is coated of hard material for greater durability.

Sleeve – Cast Cylinder in gray iron GG25 or nodular iron GGG 50, machined and with hard weld application in the grooves. All metal sleeves are produced in electrical ovens with total alloy control and solidified in metallic molding ,from what is produced a cast iron of excellent granulometry and absence of failures.

Shaft – stell forging SAE 1045 normalized, machined in numerical control machine allowing an excellent finishing. A finite elements program was used to better design the sleeve regions and adjustments, in order to reduce possible cracks and shafts fractures.

POL

How to measure the mill workExtraction or Pol%Bagasse?
Mill EMPRAL/SIMISA
How to measure the mill work

The experience more than 45 years our professionals made EMPRAL Piracicaba consolidate the concept of evaluating the efficiency of the mill work evaluating the pol%bagasse as the main factor.
We found that, regardless of the quality of sugarcane (pol% cane and fiber% cane), if observed the basic rules for a good grinding, the pol% bagasse remains almost unchanged. So we use this index as a comparison factor

If the mill tandem has 4 units, we can expect Pol% Bag. 2.5 to 2.0

If the mill tandem has 5 units, we can expect Pol% Bag. 2.0 to 1.8

If the mill tandem has 6 units, we can expect Pol% Bag. 1.8 to 1.3

But the real question is the extraction!

Then use the graphics option below.

Why we keep us up front

Why we keep us up front

It didn’t occurs by chance. The between EMPRAL is always ahead searching the best solutions for its customers, improving the mills concept. The EMPRAL mill was the first Shredder constructed with hydraulic head without bronze bushing , with piston coated with Carbodur 135, spherical socket joint and assembled with inclined keys ensuring stiffness of the housings set and the disassemble easiness, resulting in “less” maintenance.

The EMPRAL mill was the first to increase significantly the adjusting area to grind more. It was the first to design stronger shafts (higher service factor) using long radii, and the first totally machined in numerical control machines providing a larger shaft useful life.

It was the first to machine the pinions tooth bottom, reducing the premature cracks probability and cooperating in increasing its useful life. It was the first to supply mill rolls totally assembled with bearings, seals, pinions and other parts with no need to adjust, lowering the costs and expediting the assembly process at the plant. It was the first to eliminate the grease use in the housing/top bearing and to adopt the solid lubrication by graphite. The EMPRAL mill was the first to supply and deliver to the market the top roll flanges with hard weld also to increase its useful life. It was the first to supply the mill 95”.

And being once again the first to supply a mill with capacity exceeding 41.000 TCD . The mill 1570x2650 mm (61,8”x104,3”), the world's largest mill in milling capacity.

Evolution Constant:

In the last years made ​​significant investments in modern manufacturing technologies, allowing EMPRAL to improve the design of mills EMPRAL, making the mill a product in constant evolution.

Reference

Reference

Today EMPRAL is reference in the market, over 23 years supplying mills.

More than 320 mills sold, that has made EMPRAL Piracicaba the sales leader for 8 consecutive years.


See the table