The miller and milling engineer

Preface

When the writer first conceived the idea of publishing this book he had most particularly in mind the benefitting of those millers who have to operate mills in isolated places. It is not possible for such millers to gain that knowledge and experience that their more favored brethren have who are living and working in localities supplied with mills of the most modern construction and with every known system, and where it is possible for operatives to converse with each other and compare notes, exchange ideas, and tlius mutually assist each other.

There are no doubt millers who enjoy all the modern advantages that will not be interested in all that this work contains, but the writer is convinced that there are those who will, and there is a demand for a work elementary enough to aid the class of millers first alluded to and yet be of service to those of wider experience and greater opportunities. This will be sufficient apology for the mention of many details that some readers may regard as superfluous.

This work is based on the practical experience of the Viriter covering thirty-five years, and has stated facts and not theories, and writes without bias to any system, machine or principle. His sole purpose has been to produce a work that would be helpful to his brother millers.

No attempt has been made to pad these pages to an undue length; and nothing has been introduced except that which every miller should know something about. Possibly there are some who will object to the introduction of steam engineering into the work, but there are unexpected opportunities for a miller to display his knowledge in steam engineering when least expected, and there are times when millers have to operate mills with inexperinced engineers, and it is greatly to his own safety to keep a close watch on the engineer and also the engine.

Regarding tlie plans and diagrams in this work it need hardly be said that being for the instruction of those who have knowledge and some experience in the art of milling and its mechanism, no attempt has been made to show every detail, for that would make the work too expensive and difficult of accomplishment. The writer deemed it unwise to cover page after page with explanations of plans and diagrams when to men who have the least knowledge of the art they are self explanatory. It has been the desire nearest the heart of the writer to do something that would be of lasting benefit to my fellow operatives, and having worked my way from the bottom rung of the ladder until I reached the top I know what a struggle it is and I always wish to do by others as I would they should do unto me.

If this work, the result of a plan long cherished, should prove helpful to some, it will have served its purpose.

Chapter I. HEADMILLER, FOREMAN, OR SUPERINTENDENT

The most important feature in the correct running of a mill is the headmiller, foreman or superintendent, and upon him generally rests the responsibility of making a mill a success. Any mill with a capacity of 200 barrels upward should employ the very best miller possible to obtain. He should be placed in fuU control, receive sufficient compensation to make him satisfied with his position, and he should be given to understand that he must render faithful service. The headmiller must be such in word and deed; he must have good executive ability in order to rule the men placed under his supervision; he must give his orders and see that the men obey such orders; he should be conscientious, painstaking, civil, unselfish, gentle, considerate, very intelligent, and know his business to the uttermost in order to rule men and make a mill thoroughly successful. Millers are not made in a day, month or year, and in order that a man may rise to a higher plane in his profession he must study constantly, read all the milling journals and milling literature he can, and never miss an opportunity to gain any knowledge relating to his chosen calling. It is a simple matter to run a mill when one is competent, but my how hard when one does not have the knowledge, and how soon the mill is running the miller, and to see a miller in this predicament is very amusing, and there are thousands of such millers, and more is the pity. The headmiller should at all times show consideration to those under his care; he should never use profane language, and if he does he deserves a whipping; he should never show a jealous disposition; he should give civil answers to his men when asked regarding information relating to milling, for it might be of lasting benefit to the apprentice, himself, and the millowner. A headmiller ought to give the best and purest advice to those under him, for kindness in this respect will linger with them the rest of their days, and how much better to be remembered as a good man in after years and get good words, than to be thought of as a bad, domineering spirit; and how much better to be a philanthropist than a misanthropist. Avoid making enemies, it does not pay; it is often dangerous to life and property, and to study revenge is foolish and a waste of God's precious time, and alwa)s devolves on your own shoulders.

When I was a superintendent over six mills it was always a source of the greatest pleasure to give advice and instruction to those working under me, and I have had some of the most pleasant reminders from those whom I have assisted in that way; and only a )ear ago I received a beautifully pleasing letter from a headmiller who said in part, "7/ it had not been for your friendly advice I would have been a laboring man today;" and such words are well worth all the trouble it gives one.

Millers should at all times guard against the affliction known as self conceit, for we never know it all, and I have received some very valuable tips from my understudies, and not because I did not know how to do a thing, but he taught me how it could be done more expeditiously.

Self conceit leads many a man into the idea that he knows all about the correct running of a mill just because all is running so smoothly under his headmiller, and at the first opportunity he risks his reputation and accepts the headmillership, only to find that the mill is running him instead; and my advice to such men is to stay under a good headmiller until thoroughly competent to operate a mill correctly.

To gain a higher position a miller must attend strictly to business, have your employer's interest uppermost in 3'our mind at all times; study all possible in the time that others are wasting foolishly; keep eyes and ears open to gain every advantage possible that will spell advancement in your chosen field; know the why and wherefore of every machine in the mill and how to adjust its every part; never think you know everything there is to know, for therein you fail in ever being a competent miller.

Should you at any time desire an advance in salary take that desire to the millowner, superintendent or manager; place it before him in a mild and concise manner, and in turn, give tliem time to think it over carefully before deciding, and invariably it will be forthcoming; but should we go to them in a blustering manner and demand an advance or we would immediately resign, in all probability the resignation would be accepted, and often taking effect at once.

Unless you have made up your mind to sever your connection with your firm, do not fly into a tantrum and say, "If so and so is not done I will resign," for you might be let out at a moment's notice, which might prove very inconvenient in many ways, and especially financially. As a little example of the way such matters turn out I relate the following:

The superintendent of a large factory would, upon the least provocation, fly into a tantrum, rush to the office, and even curse the proprietor and say if so and so was not done he would leave at once, and being a very valuable man the proprietor would pacif)- him and all would be well. One da)' he did that very thing when a son, just out of college, happened to be in the office, and after the superintendent had gone into the factory, he said to his father, "Father, what would you do should that man die, for r know that this factory could run without him?"

The father's answer came immediately, "How strange I never gave it a thought in that light. Call him and pay him off forthwith"; and his place was filled at once. Always remember that a man is never so valuable but what another can be found to fill his place, and very often for the better.

A headmiller ought always to be given sufficient assistance to run his mill correctly, and should have something to say in regard to the men who are to be his assistants; and should really be allowed to hire his own men, and should be held responsible for them and their work.

In American mills, generally speaking, there is an insufficiency of helpers allowed, and the headmiller is often called upon to do work that would be more profitable to be left to cheaper help, and the mills are run with much less help than mills of like capacity in the old world.

Millowners should not expect their millers to be responsible for their mills and the products and at the same time expect them to attend to customers, oil the mill, do the cleaning, grinding, grading, purifying, wheat cleaning, and all manner of roustabout work, for it is penny wise and dollar foolish policy, and everything generally becomes as it ought not to be, and the result generally a mill that is a failure.

The miller that is running a mill under the above conditions is never satisfied with his position if he may be called a miller; and should a good customer happen along when the miller was in the midst of a choke, and had to wait an hour, or until his patience was e.xliausted, he would undoubtedly leave not to return, which would cost the owner the price of another hand to do such work.

Millers should never undermine their brother operatives; it is cowardly, dishonorable; it never gains them anything, but on the contrary they are invariably out of emplo)'ment. They should at all times lend their brothers all the assistance they can, and should they get out of a position take the next best thing to be obtained to hold until such times as an opportunity presents itself to re-enter the mill in an honorable manner, but not to go and undermine )Our brother by offering to run the mill at so much less salary, and many do this very thing. I know of an instance where the superintendent of a large mill was sent on a visit to Europe at the mill's expense to gain all the knowledge possible, and while he was absent his headmiller undermined him completely, and he stepped out.

There are headmillers that deserve all that can possibly come to them, and there are some that really know so little about milling that deserve all they generally do get, and should a man come along at the time they are going to be let out it is no fault of theirs if they secure the the position if offered them. It was my lot when starting up my second roller mill to have a foreman that was one of the meanest men it has ever been possible to meet anywhere; it was impossible to get out of him a civil answer; would sneak around to do dirty mean tricks, instead of being a man to stand up and tell what he desired, and such a man ought not to have charge of men. Again there are a class of men in mills that will stoop to the most dastardly meanness that is possible, and will resort to anything in order to get even for what are often imaginary wrongs, and I have had men that I have assisted in man)' ways and who were jealous of me, throw off belts, place obstacles in spouts, perforate bolting cloths, etc., and were sometimes found out and discharged.

There is in a mill a place for every man; ever}^ man should be in his place and know that place; and that man should have a place for everything and everything should be in its place; and always remember that if anything is worth doing it is worth doing well.

If a man is a miller in every sense of the word he will be able to fill any place in a mill, and patience and study will assist him in gaining the summit of his profession.

To get the best there is in the workmen it is well to be kind and affectionate one to another at all times.

Chapter II. KEEPING THE MILL CLEAN

Nothing is more revolting to a man or miller of refined sensibilities when going into a mill and finding it in undisturbed possession of oil, tobacco spit, cobwebs, dust, dirt, bugs and all the innumerable concomitants of the slovenly miller, and how a competent miller can work in such a place is be}-ond my comprehension.

There is no place that gives greater delight to a real miller than that of a mill kept in that perfect order a mill should at all times be kept, and what is there that is prettier than a mill that is neatly painted, spots varnished, shafting as bright as bells, machinery free from grease, floors free from oil, walls whitewashed, every corner clear of dirt and dust, bugs an unknown quantity, and tobacco juice not in evidence?

If a mill is kept spotlessly clean in every part it is seldom in possession of bugs or vermin, for they can not thrive in a clean place as a general rule, yet how many mills )'ou see with every corner piled like a pyramid with flour and meal, making them a breeding place for all manner of insects.

It is difficult to be neat and orderly unless the instinct is there, but perhaps a few observations may serve to show the lax brothers where to begin. There is no ploce on the wall or floor of a mill for anything but what is absolutely necessary for the correct working of said mill; if the article is small, have a receptacle in a convenient place for it; if large hang it up in a convenient and unseen place.

When the mill floor and walls are free from unnecessary articles of every description, it is an easy matter to keep the mill looking spick and span at all times, and for the simple reason that dirt can not be hidden. The sweeping and cleaning of a mill seems very simple, but I assure you there are few who really know how to do it, and one thing is to be borne in mind: "Take care of the corners and the open spaces will take care of themselves." It is a fact that there are operatives in charge of mills today that could not hold the position of a sweeper in our large mills for the reason that they can not sweep clean.

Machinery requires cleaning daily; the floors require cleaning whenever necessary. Do not leave empty bags, twine, meal or anything around, for they are liable to catch fire from spontaneous combustion.

All the spare time of employes ought to be given to fighting dirt, cleaning and brightening all shafting; cleaning off grease from every part, and in this way the mill can be kept clean.

There are mills that I visit in which it is difficult to distinguish between wood and iron on account of the perfect way in which oil and dust have done their work, the bearings being unrecognizable in many instances. A putty knife is one of the best instruments to clean the grease from floors and machinery, and it is handy because it may be carried in your pocket; and it is also handy in tightening up a screw when in a hurr)'. I have often been astonished how anyone could use the flour of some mills that I liave seen in my travels, for they were littered from basement to roof with all manner of filth, and how any man, and especially a miller can work in such a place is bejond my comprehension; but they were always loafing when they had an opportunity to shine up. A clean mill is a valuable asset in building up the trade of the mill and retaining that trade, and when it is kept spotlessly clean it is soon known far and near, and the products become known as being made in a spotless mill. It is a good advertisement for any mill to have a visiting day, when your townspeople can be invited, and demonstrate to them just how the flour is manufactured, and you will be astonished how the women will talk about it to ever}'one the)' meet for days afterward. All people speak well of a clean mill, but a dirty mill is an eye sore to all people; so mv advice to all is to have a clean mill or no mill at all.

Chapter III. GRAIN ELEVATORS

Grain elevators ought to be planned and diagrammed by an expert in the receiving of grain of every description. The building should be alongside of the railroad to receive and ship the grain and products that may be manufactured; all grain should pass the first stages of the cleaning in the elevator so as to prevent any dirt or dust passing to the mill; all feed ought to be ground in the elevator when in connection with mills of 200 barrels capacity and over. The other side of the elevator from the railroad ought to be arranged for an easy entrance for farmers' wagons; with dump for all grain; with scale in connection with the dump, and everything ought to be of the most modern construction, with the weighing and receiving arrangements the most simple in order to get the farmers, for they generally take their grain where there is the least work in unloading. Be sure to have the capacity of the receiving elevator above the capacity rather than below, and a saving in first cost in this instance becomes very expensive when they are in actual operation, and the buckets ought to be at least sufficiently large to receive 1,000 bushels per hour for small elevators, then there is no time wasted by the men as very often is the case with elevators that are too small.

When building an elevator it is well to eliminate all conveyors when possible, and it can be done by having the elevator heads high above the receiving bins; and the boots sufficiently low to allow the fall.

Wheat only needs about 30 degrees to travel down a spout when the wheat and spout are in good condition. All grain should pass a receiving separator before being sent to the receiving bins in order to remove everything larger than the grain passing, or there is all kinds of trouble when drawing the grain from the bins by choking at the slide.

The elevator foreman ought to be a very reliable man, one who is a good judge of wheat, and to be able to test his grades, detect all the diseases prevelant in grain, and to be a judge of the moisture contents of the same.

The foreman ought to be a miller by trade in order to attend to the manufacture of all kinds of feed. An elevator should be built very simple, and very strong, and with all machinery above rather than below capacity, which prevents chocking, saves much time and expense, and it is always ready to receive the grain in a hurry which is very often the case when several cars arrive at one time, and wagons galore awaiting their turn on the otherside to be unloaded.

Again, the foreman ought to be a fair mechanic, for it falls to his lot very often to repair tilings in a hurry, and there is little time to send and await the arrival of a millwright or carpenter.

The foreman must be a pleasant and congenial personage in order to ingratiate himself into the good graces of our farmer friends, for they are very appreciative for favors as a general rule, and they are very quick to resent any inattention on the part of mill officials.

The foreman must be as sharp as a fox in order to detect the deception of some farmers, for there is nothing too low for some of them to stoop to to gain an advantage over the mills or elevators.

I have caught farmers doing the following: Weighing themselves on the load and trying not to be weighed as tare; mixing in sand, screenings, rocks, and even water; also weighing their foot, sacks or anything else it is possible to do. A passenger elevator is absolutely necessary in an elevator in order to have the men do their utmost for employers, for if an emplo)e has to climb to the top of an elevator several times daily he is of little use for other duties.

The arra:ngement for delivering wheat to the mill for grinding must be at the command of the miller when necessary, or at the signal from the mill; and should be sent to the mill by a spout rather than a conveyor whenever possible, for it is a saver of power, it is less expensive in every way, and the wheat reaches the mill more expeditiously.

All elevator legging in an elevator ought to have an e.xliaust attachment so as to draw in all dust and make it possible to keep a clean house, for it is the best of policy to keep it as clean as the mill, and it can be done.

Chapter IV. THE BUYING OF GRAIN

Just as much discrimination is needed, as much judgment can be exercised, and as much profit made in the purchasing of wheat as in any other branch of the milling business.

There are many things to guard against when buying wheat or any other kind of grain, and it behooves all grain buyers to be constantly on their guard, or they will be caught napping to their detriment.

A good and competent grain buyer will detect instantly the defects of wheat brought to him to pass upon, and there are a great variety of diseases prevelant in wheat.

When buying wheat it is necessary to guard against the following: Smut, must, sprout, weevil, binburn, immaturity, white caps, cockle, chess, amount of screenings, amount of moisture, sand, gravel, actual test, and anything that is not a grain of wheat.

Always pay higher for the dark flinty berry than that of a white chalky nature, for the former is more profitable in every way, and it makes better flour.

Smutty wheat is very obnoxious on account of the offensive odor, which is very difficult to remove, and should the smut ball become damp during the harvesting the smut ball bursts, the black, grimy and very foul smelling dust becomes embeded in the fuzz end of the berry, and also in the crease, and the only way to put the wheat in milling condition is to pass it through the laundrying process, where the wheat passes through a stream of clear water, only remaining in the water about a minute at the most, when it passes to the dryer before the bran is soaked through, and it is easily dried.

Must is the very worst of wheat diseases for the reason that it is not possible by any known process to remove the obnoxious odor.

Wheat mixers will mix and scour and rescour to try and deceive the bu)'er, and I have seen some sharp buyers taken in by it to their sorrow. Sprouted wheat may be blended with good wheat according to how badly it is damaged, and it is known by the small sprout adhering to the germ end of the berry.

Bin burnt wheat has a peculiar odor unable to describe, and differs from sprouty grain because it is dr)', and the sprouted is generally damp.

Immature wheat is devoid of starch and is not good to grind unless blended with good wheat.

The moisture test is one to guard against when bu)ing grain, and on corn especially or much money can be lost. The average moisture of wheat is about 12%, yet it will carry as high as 19%, and on your purchase you ought to be allowed for the extra moisture.

Weevil eaten wheat is very bad to treat if allowed to stand too long, as there is a very foul smelling dust from the refuse of the weevil when mixed with the wheat dust, and it becomes embeded in the fuzz end and the crease, and it is hard to remove.

When buying, be very careful to get all that is coming to you, but it is very unwise to try to take any advantage of a farmer, for if he finds it out it passes to others like wildfire, and tlie mill is often ruined; but on the contrary, do not let the farmer take advantage of you, for he will do that very thing up to 50% of them.

The only correct method of purchasing wheat is by test, and the half-bushel tester is the most accurate for this purpose, and it ought to be filled by pouring in the wheat, but upon no account to knock the tester, or you make 58 pound wheat test 62 pounds.

The standard ought to be 60 pounds test, and for every pound over test allow one ceht per pound; and for every pound under 60 pounds deduct one cent per pound to 56 pounds, when you ought to deduct two cents per pound to 52 pounds, and below 52 pounds it may be bought for chicken wheat or for feed.

The above is on sound wheat, but on infected grain you must use your own judgment, and if you buy it at all get it as cheaply as you possibly can, or there is no money in its use.

In some states the mills and elevators are allowed to dock the farmers for chess, dirt, etc., and they ought to be docked for it, for if the>- are paid for it they soon mix more of it whenever possible.

The best and only method when buying wheat is to run it over a separator, the machine to be where the farmer may see it; and give the farmer his dirt and screenings; or a better method is to buy the screenings at the best price and sell them for chickens, or grind them.

If the farmer takes the screenings back to the farm )-ou get more seeds the next year, or you give him a chance to mix them with another batch of wheat and take and sell it some place where they do not use your separator method.

In olden times it was a criminal offense to walk across a barn, or warehouse floor when anyone was testing grain, and it is well to think about that very thing when filling and stroking the tester; and the tester must be stroked with something square, with a perpendicular side in front or it has a tendency to push the wheat into the tester.

It is dangerous to bu)' damaged wheat from a farmer if you are running a country mill, for he will tell all his neighbors about it, and then you will have complaints about }our flour.

If a farmer insists upon giving you off grade wheat on exchange just tell him to wait and you will give him flour from his own wheat, and I warrant you he will not insist longer.

Every farmer has the best wheat in the county when he comes to the mill to dispose of the same, but be on your guard with them, for you will often find good at the top and bottom of the bag and bad or unsound in the center.

Treat all farmers equally and you will make many more friends for your future welfare. a;-t^

Chapter V. THE AVHEAT BERRY AND ITS COMPOSITION

Wheat has been cuhivated since before the time of the building of the Pyramids of Egyt, and in all probability from the creation, and planted by God for the very purpose for which it is being used today.

There is no doubt but what it belongs to the family of grasses, and by cultivation has been brought to its present stage of usefulness to man and beast, and without doubt the most useful grain that is produced from mother earth.

Wheat is generally known in two species as summer and winter, or more commonly called spring and winter, but there are many varieties and from many different countries; these species are divided into many different varieties such as Egytian, East Indian, Australian, English, Russian, Turkey Red, white, red, amber, hard spring, medium hard spring, hard winter, medium winter, soft winter, durum or goose, yellow berry, blue stem, etc.

There are wheats testing from 50 lbs. to 66 lbs. per measured bushel, the former being very shrivelled and gradually filling until it reaches the grains fully enlarged to make perfect wheat.

Soil and climate have everything to do with the growing of wheat and giving us spring, winter, hard and soft varieties.