Crushing Mechanics and Flour Properties of Wheat Under Different Graded Crushing Durations in a Blade Crusher

This study investigates the effects of different graded crushing durations in a blade crusher on the crushing mechanics of wheat and the properties of the resulting flour. Mechanical models were established for blade-particle collisions, radial sliding of particles along the blade surface, and particle-chamber wall collisions. Under reasonable simplifying assumptions, the models analytically characterize the theoretical relationships of impact force and crushing energy with blade rotational speed, rotational radius, and particle incidence angle. The models were used to provide a qualitative mechanistic interpretation of the experimental trends rather than to quantitatively predict flour particle size distribution or damaged starch content. Two graded crushing processes were evaluated, with crushing durations of 10 s per pass (F10) and 15 s per pass (F15). Observation of particle-size evolution during the crushing of wheat particles showed that as the number of crushing passes increased, the proportion of coarse particles continuously decreased, the proportion of fine particles gradually increased, and the proportion of intermediate-sized particles initially increased and then decreased, demonstrating a progressive coarse-to-fine fragmentation pattern. Particle size analysis of the resulting wheat flour showed that the particle size distribution for the F15 process peaked below 5 μm and shifted toward smaller particle sizes relative to that for the F10 process. Nevertheless, the wheat flour obtained from both processes exhibited relatively concentrated particle size distributions, with Span values ranging from 2.46 to 2.68. Damaged starch content increased significantly with the number of crushing passes and was generally higher for the F15 process than for the F10 process. Moisture content decreased from 14.30% to 12.86% under the F10 process and from 14.25% to 12.73% under the F15 process, whereas ash content ultimately increased to 0.48% under both processes. Protein content initially increased and subsequently decreased under both processes. These findings provide experimental evidence for the effects of graded milling on grain refinement, starch damage, and physicochemical composition of wheat flour.