Bühler has launched the OLFC, a new flaker system for processing oilseeds, designed to help processors achieve higher productivity and maintain continuous operation.
The Bühler OLFC flaker features a robust structure that reduces vibration by up to 25 percent compared to its predecessors, along with larger rolls that more than double service life. Integrated sensor technology, automation and connected digital services give operators real-time insights into machine performance, supporting early identification of maintenance needs and reducing production disruptions, as reported by the company.
Flakers are used in oilseed processing plants to press cracked seeds such as soybean, canola and sunflower into thin flakes before oil extraction — a step that runs continuously. Each OLFC can process up to 500 tonnes per day, according to the company. It notes that flaking plays an important role in oil extraction, as the size, thickness and thickness consistency of the flakes influence extraction efficiency downstream.
To address reliability under continuous operation, their 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. According to them, these changes reduce machine vibration by up to 25 percent while creating a more robust platform for long-term operation.
The system features larger rolls with a diameter of 820 millimetres, compared with the industry standard of 800 millimetres. Combined with an extended usable diameter, the company states this increases roll service life by 150 percent, reducing replacement frequency and lowering total cost of ownership. The system also includes an upgraded hydraulic system to protect against sudden pressure spikes, including those caused by foreign objects entering the equipment.
According to the manufacturer, the OLFC uses a timing belt that transfers power more efficiently than conventional belt systems, consuming up to four percent less energy than its predecessors. An auxiliary drive rotates the rolls at low speed during grinding, allowing safer and more efficient roll service. The company estimates that 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,” said Lukas Spannagl, R&D Project Manager Value Nutrition at Bühler. “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.”
The new system integrates mechanical improvements with a redesigned automation system. A new touchscreen gives operators a real-time view of machine status, while an integrated sensor system provides performance insights. Operators can consolidate data from multiple flakers using Bühler Insights, the company’s digital platform for machine monitoring and analytics.
“To make operation of the machine as seamless as possible, we have adopted a more intuitive design language that operators inherently understand,” said Abdulqadir Abshir, Product Manager Value Nutrition at Bühler. “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.”
According to Bühler, the new system was developed in close collaboration with customers across major oilseed processing regions, including North America, Europe and China. The design was validated through two prototype installations at soybean processing plants in the United States, with one unit operating under real production conditions since October 2023. Following successful validation, the OLFC is now available worldwide.
