Bratney & OMAS Enhance U.S. Milling

Bratney successfully partnered with a large-scale flour mill in the eastern United States to implement the innovative Omas dry scrubbing technology (DST), marking its first installation in a mainstream U.S. facility. The project delivered transformative results—including increased flour production, improved quality, and reduced ash content—while cutting tempering time by 20–30%. By optimizing scouring processes and freeing up valuable tempering space, the mill achieved greater efficiency and profitability, with an estimated payback period of just 11–16 months. This case study highlights Bratney’s ability to integrate advanced solutions into complex milling operations, driving both operational excellence and financial gains.

Project Background

Bratney was selected for this project to install the Omas DST system in a large-scale, mainstream flour mill located in the eastern United States. The DST system represented a significant advancement in scouring technology, replacing traditional dry scourers prior to tempering. Designed to deliver more aggressive scouring action, the Omas DST enhances flour production, reduces tempering time, and improves the cleanliness and quality of both wheat and flour. The system, initially implemented for hard red spring wheat, is versatile enough to support hard red winter wheat as well, offering a broad application range for mills processing multiple wheat types.

One of the key achievements of this project was the measurable improvement in clean wheat and cumulative flour ash levels. Before installation, clean wheat ash averages ranged from 1.47% to 1.51%, depending on protein levels. Post installation, clean wheat ash

averages dropped by nearly 0.10%, and cumulative flour ash levels reduced by 0.06%. The DST system also provided a notable increase in flour production rates, rising from 76–77% to 78% extraction while cutting tempering time by 20–30%. This allowed the mill to reduce the number of tempered wheat bins from 2–3 down to just one, freeing up critical space and enhancing operational efficiency.

Utilizing Bratney’s in-house design, engineering, and installation services, this installation marked the first use of the Omas DST system in a mainstream U.S. flour mill, showcasing its ability to drive both operational and financial improvements. With an estimated payback period of 11–16 months, depending on filter capacity requirements, the DST system offers a compelling option for mills looking to boost output, optimize tempering processes, and achieve superior product quality. The project's success highlights Bratney’s expertise in integrating innovative technologies into large-scale milling operations to deliver measurable results.

Project Scope

Process Engineering
Project Management
Millwright Services
Equipment Selection
Equipment Installation
Facility Startup
Operator Training

Project Details

Bratney designed process flow and layout for DST equipment.
Reduced maintenance on sifter (first break) from approximately 6 months to 10 months.
Bratney managed the project from design to final startup, including installation.
Improved sanitation for mill in general and the plansifter.
Installed two Dante machines, cyclones, fans, and a filter, including spouting and ductwork.
Reduction of ash content in wheat.
Provided startup and training services.
More than 1% flour production.
Less water evaporation.
Reduction of temper time by 20-30%.