Grain Innovation Center Bühler

Bühler’s new Grain Innovation Center in Uzwil is where new creations are made from an extremely wide range of grains and much more. Siemens technology ensures that around 70 systems – from sorting screens and grinders to fans – work together both seamlessly and efficiently.

Bühler opened its Grain Innovation Center (GIC) in Uzwil in October 2024 to comprehensively test both new innovations in the industry as well as new processing processes. Innovative processes for the food and animal feed industry can be put to the test in this five-story test center, which features 2,000 m² of floor space and more than 70 machines. According to Lothar Driller, Department Manager Feed Application Center at Bühler: «With the GIC, Bühler has created a versatile test center: Its focus is on topics like process optimization, energy efficiency, maximum availability (in part through the use of predictive maintenance).

The big picture

Bühler handled all of the engineering-related aspects of the GIC itself but relied entirely on Siemens technology for the automation and drive technology. This project’s big challenge lay in the end-to-end, future-proof automation such a large test center, including the seamless integration of the safety functions. Numerous components like motors, frequency converters and controls as well as components from the realms of industrial switching technology and low-voltage power distribution work together in perfect harmony on this «playground for millers».«Hammer mills used in animal feed production, for example, rotate at high speed and crush the material by spinning,” explains Driller. “The motor has to cope with a high initial load – something referred to as heavy starting. That’s handled by Sinamics G220 high-performance frequency inverters with precise speed and torque control, flexible hardware and software options and integrated safety functions. We appreciate the way the PLC and the HMI seamlessly interact in the TIA Portal. Another plus: Even if a customer provides small samples for testing, precise control lets us adjust the grinding speed to optimize the process parameters».

The right start for every motor

The shear forces created by rollers rotating in opposite directions make the grinding done by roll mills somewhat gentler than grinding in a hammer mill. To reduce the strain on machine parts, compact Sirius 3RW soft starters let the electric motors start up gently. After start-up, integrated bypass contacts ensure that current flows directly to the motor for energy-efficient operation. The status monitoring function provided by the soft starters makes it easier to plan maintenance work, thereby maximizing system availability. Powering the many fans is easier, but no less important for the system. They prevent dust from accumulating – dust that could potentially cause an explosion. The fans are actuated via Simatic ET 200SP motor starters. Real-time measurement of the rated current and comprehensive diagnostic data make it possible to precisely assess the fans’ operating status.

Valuable data

Each of the GIC’s five floors contains up to ten control cabinets equipped with Siemens components. “A reliable power supply is essential for us,” emphasizes Stefan Suhner, Head of Automation Milling Solutions at Bühler. The control cabinets’ main switches are Sentron 3VA compact circuit breakers with an integrated measuring function for current, voltage and energy values. They can be easily integrated into higher-level energy management and automation systems via common bus systems. This concept prevents failures, optimizes processes and sustainably increases the efficiency of the entire system.In the Grain Innovation Center, all machine and process data is recorded centrally via the TIA Portal, enabling Bühler to conduct targeted evaluations and functional tests on this basis – from the raw material feed to processing and the finished product. The TIA Portal combines hardware and software: It enables the real-time analysis of data such as energy consumption, temperature or engine load, which is collected via frequency converters and starter components. Bühler uses this data to optimize processes, test new formulations, and evaluate the efficiency of individual machines or entire lines.

Bühler Referenzbericht Sirius Sanftstarter 3RW

Sirius 3RW soft starters

To reduce the strain on machine parts in the Grain Innovation Center, compact Sirius 3RW soft starters allow the electric motors to start up gently.

Simatic HMI

The Simatic HMI provides all important information at a glance in the Bühler Grain Innovation Center.

Sinamics G220

Sinamics G220 frequency inverters master heavy starting and optimize process parameters – even for small test samples in the Grain Innovation Center.

Power supply

A reliable power supply is the be-all and end-all at the Grain Innovation Center.

Ten control cabinets

Each of the GIC’s five floors contains up to ten control cabinets equipped with Siemens components.

Sustainably into the future

It took around three years to develop the GIC from start to finish, with Siemens joining at about the midway point. Suhner has fond memories of this time: “For Bühler, Siemens is more than just a supplier. It’s a reliable partner. We’re more than satisfied with the technology. Everything is running smoothly and not only are our own tests working perfectly, but our customers are enthusiastic about the GIC as well. We’ve received lots of interesting inquiries and are very well booked.” The flexible system is the outward sign of a promising collaboration between Bühler and Siemens: “If we want to test new technologies that are useful for this application in the future – like a digital twin – Bühler is open to the possibility. We look forward to future innovations and joint developments at the GIC,” says Alessandro Pepa, Siemens Global Account Manager for Bühler.