We design, fabricate, and integrate processing systems for all types of bulk dry solids, powders, and some slurries. Whether it’s food, pharma, or industrial, there is a best method for feeding, grinding, blending, and sorting everything. We find those solutions and make sure they’re integrated properly. Below are the most commonly recommended solutions.
Volumetric feeders estimate the amount of product being fed based on the feeding mechanism’s speed (vibration intensity/screw speed) and known average product consistency.
Gravimetric feeders measure the actual amount of product being fed by placing the bin, feeder, etc. on load cells and stopping the feed when the target weight is reached.
Loss-in-weight feeders operate similarly to gravimetric feeders and allow continuous feeding of product. They dynamically compare the weight of the feeder’s tank to the weight of the product being fed into it.
VIBRATORY & SCREW FEEDERS
Though typically classified as their own type of feeder, these are means of controlling product flow. Vibratory and screw feeders can be volumetric, gravimetric, or loss-in-weight. Vibratory feeders vibrate slightly sloped channels, causing product to flow evenly. Screw feeders employ high shaft-to-thread ratios, minimizing packing and density differentials.
MILLING & PARTICLE SIZE REDUCTION
Jet mills utilize particle-on-particle attrition to grind product. The Micronizer® is the most popular jet mill in the world, employs a unique fluid energy grinding system to produce sub-micron sized particles, and avoids the generation of heat during the milling process.
Pin mills use shafts to break up either solids or fluid suspensions with repeated impact. They’re ideal for milling particles down to a few micrometers when heat will not degrade the product. The Simpactor® is a centrifugal, high-speed, screenless pin-type impact mill that reduces low to medium-density materials to uniform sizes of 50-200 mesh.
Hammer mills crush product with swinging bar hammers and screen particles with grates and screens. They are a general solution for milling most friable materials from pharma and food to chemicals and limestone. HAMMERMILL® capacities range from ½ – 6 tons/hr.
INFESTATION CONTROL MILLS
Infestation control mills kill insects without the use of chemicals. The Infestroyer® accelerates product by centrifugal force through a single set of whirling rotor pins. Impact with the pins and corrugated wall destroys larvae, eggs and insects ensuring 100% kill without over-grinding the product.
Roller mills employ roller-to-roller or roller-to-plate methods to crush product into granules while minimizing powder. The Roll Crusher® offers material reduction up to a 4:1 ratio and from ¼ – 44 tons/hr.
Disc Mills create uniform product for materials like chemicals, ceramics, minerals, and glass. Sturtevant’s Sample Grinders can produce particulate as fine as 100 mesh and come in capacities from 50-800 lbs./hr.
Jaw Crushers use jaw plates to compress and shear product into coarse & intermediate particles. Sturtevant’s models offer material reduction up to an 8:1 ratio and from ½ – 10 tons/hr.
Filtration systems remove undesirable fines from airstreams resulting in better products, healthier air, and reduced exposure to fire and explosion risk. Schenck process is one of the longest-standing authorities in this field and offers a method and size to fit every application.
SEPARATORS & CLASSIFIERS
See these separators and classifiers in action at Kason’s site.
Cross-flo static sieve screeners & separators are for solid/solid or liquid/solid separation. They are electricity-free and remove oversized particles from free-flowing bulk dry solids or solid materials from wastewater at ultra-high rates.
Vibroscreen sieve screeners & separators classify, de-dust, sift, or de-lump bulk dry solids or solid-laden slurries. These vibratory screeners separate product into up to 5 sizes using different sized screens which can be changed based on the application. FLO-THRU models are also available for applications with particularly stringent height parameters or high temperatures.
The Centri-Sifter uses centrifugal force to propel materials against the screen of the cylindrical sifting chamber. The helical paddles used to perform this action avoid contact with the screens while breaking up soft agglomerates and ejecting over-sized and unusable particles. This solution by Kason is the ideal choice for continuous scalping of dry or moist materials, even those that tend to clump. It is also particularly effective at separating liquids from solids.
Air classifiers can range from a few cubic feet to 40′ high and 26′ wide. They sort dry product by particle size for product de-dusting and improved grinder performance. Available in both stationary and mobile units, the largest option is the Whirlwind®, which is self-contained and does not require process dust collection equipment. It can separate powders in the range of 100 to 400 mesh (150-38 microns). The Side Draft also operates in the 100 to 400 mesh range, but additionally features variable speed controls. The SuperFine Air Classifier is used to separate powders in the range of 5 to 44 microns.
DRYERS, COOLERS, MOISTURIZERS
The Vibro-Bed uses air & vibration to maximize material’s surface area and therefore the rate at which it can be dried, cooled, or moisturized. Kason’s solution features circular processing units which are inherently stronger, lighter, and less costly to build and finish to sanitary standards than their rectangular counterparts while having the same surface area.
And because the circular fluid bed processor is more compact, complete fluid bed systems can be pre-engineered and pre-configured on caster-mounted frames, for turn-key operation. They come in sizes from 18 to 84 inches diameter for laboratory and pilot testing or high-volume processing.
BLENDERS & MIXERS
Paddle Blenders have U-shaped horizontal troughs and paddles moving product in opposing horizontal and vertical directions. Paddle blenders are typically used for feed and grain, non-directional slurry mixes, soap pellets, particulates, abrasive products, pastes, filter cakes, and fragile/friable products. They’re also used for effective mixing of significantly under-capacity batches.
Being one of the oldest mixing methods, ribbon blenders are out-dated for some applications but remain the best for others. They have u-shaped troughs with opposing sets of helical agitators, one inner, and one outer. By forming 2 opposing cyclones within the product, they create homogeneous mixes quickly but create minor amounts of heat and can degrade the product.
Plow blenders are well-suited for applications requiring vacuums or high pressure. They use wedge-like plows attached to a high-speed rotor to lift the product and create a weightless effect, helping negate problems caused by differences in particle size or density. They’re adept at mixing solids to solids, liquids to solids, and solids to liquids for a wide range of applications.
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