conemill 11 x 17 - kemutec · swings down complete with the cone - which can simply be lifted out...
TRANSCRIPT
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CONE MILLS
LOW ENERGY SIZEREDUCTION FOR THEPHARMACEUTICAL,FOOD AND CHEMICALINDUSTRIES
kemutecSpecialists in Powder Processing Technology
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THE CONE MILLING CONCEPT AND ITS BENEFITS
Cone milling is a low energy size reduction concept
ideal for fatty, heat sensitive, sticky, moist or otherwise
difficult to grind products. It alleviates the noise, dust
and heat problems associated with traditional milling
techniques at a stroke.
A gentle grinding action, capable of control within fine
limits, maintains a close particle size distribution with
minimal fines generation.
Because the residence time required to process
product is very short, heat generation is negligible,
and build up is drastically reduced - even for moist or
sticky products.
The inherent benefits of cone milling are rapidly
becoming universally accepted. Kemutec engineers
have developed a range of machines to meet the ever-
growing demands of today’s
pharmaceutical, chemical and
food industries.
Material to be processed is gravity fed into the milling
chamber. The low velocity Grinding Rotor forces the
feedstock into a vortex flow path. The individual
particles of unground product are centrifugally
thrown out to the wall of the conical grinding
chamber against which they then rise in a spiralling
path. The action of the Rotor against the grinding
chamber wall imparts high shear on the product. A
very large percentage of product is reduced to below
the cone aperture size on initial impact. This is
instantaneously discharged into the mill discharge
chute. The chute is designed to give maximum free
space to exiting material, thus preventing the
possibility of build up.
A small percentage of larger unground particles
continue their path up the conical wall within the
product vortex undergoing further size reduction in
the process. The very largest may eventually reach
the top of the vortex where they re-enter the in-feed
streamto repeat the cycle.
cone mills
User benefitsHigh efficiency - Virtually all the energy
input is utilised in the size reduction
process.
Gentle grinding action - Permits
uniform size distribution, resulting in the
minimum of fines.
Low heat generation - essential when
milling fatty, sticky or heat sensitive products.
Low dust levels - No need for air filtration. Keeps
installation costs to a minimum.
Low noise - No costly acoustic protection. Mobile
units can be used in any location.
Flexibility - Free standing mobile units, standard
models as part of process systems and special,
bespoke units as an integral part of other capital
equipment.kemutecSpecialists in Powder Processing Technology
Ultra-Hygienic Designs
Cleanability was a high priority during the design ofthe new mills. Generous radii, large accessible gapsbetween components, mostly tubular stainless steelsupport frames and cast mounting blocks for fittings,all contribute to maximum hygiene.
All models can be cleaned with high pressure hoses;electric interlocks are housed in enclosures orbeneath the covers they protect, and access coversand motor shrouds are sealed with easy to remove‘U’ section silicone seals.
Constructed of 316 grade stainless steel,the new KEK Cone Mills are availablein a variety of finishes includingbead blast, crack andcrevice freewelds and mirrorpolished finish.
The bearing housings - criticalcomponents in any mill - aresecond to none. All bearinghousings are bench run-in beforefinal assembly into the mill, andare designed to run under fullysubmersed conditions. Provision isincluded for air-purging whererequired.
High Integrity Grinding Media
Each cone is formed from a pre-punched development, totallyeliminating all part or blindapertures. Complex fixingflanges and cone caps havebeen eliminated, ensuring thatcones are easy to remove, handle, clean andreplace. The rotors are one piece components,bead blast or mirror polish finished as required.
Innovative Cone Retention
Changing cones could not be easier. Captive swingbolts release the hinged milling chamber whichswings down complete with the cone - which cansimply be lifted out and replaced.
Novel Rotor Adjustment
Much of the appeal of cone mills is the flexibility of thegrinding media - which can be changed easily, quicklyand safely, with the minimum of disruption toproduction. Another patented innovation is the easilyadjusted rotor/cone clearance. The retaining nut issimply loosened and the rotor turned to anotherposition. The rotor drive dogs pick up on a series of
alternative castellations on the rotor, all of whichare machined to a different depth. Theretaining nut thread is orientated to ensure that
it cannot come loose during operation.
Engineering At Its Best
There are nooperations which require three hands; there’s
no guess work as to how tightly gaskets should becompressed; and swing bolts may be allowed toswing without fear that they’ll mark highly polishedsurfaces.
We’ve paid all the attention to safety and easytransportation you would expect from Kemutec. Theinnovative features and quality design found in thisnew generation of KEK Cone Mills will set them apartfrom the competition for years to come.
THE RANGE
Kek manufactures a wide range of Cone Mills from
the worktop mounted ‘75’ Model through to the ‘680’
capable of a process rate up to 10 tph. Although we
offer a comprehensive range of standard design
Top driven belt drive
• The standard for ‘hopper feed’
installations
• Offers the option of speed
change via pulley sets
• The most versatile arrangement
machines, each model in the range is capable of
being customised to suit each customers’ individual
requirements.
The current range
Our extensive applications experience over the
years, during which we have responded to the ever
changing needs of our customers, has resulted in a
Customizing options - Drives
comprehensive range of drive options from
which we select the best for your requirements.
Model Cone Use Top Top Under Under In-line Grinding eludomnevird nevirdnevirdnevirdaiD
direct belt direct belt onlydrive drive drive drive
75 75mm Lab •120 120mm Lab/pilot •170 170mm Pilot/production • • • • • •220 220mm Pilot/production • • • • • •340 340mm Production • • • • • •540 540mm Production • • • • • •680 680mm Production • • • • • •
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cone mills
kemutecSpecialists in Powder Processing Technology
In-line under-driven belt drive
• No drive shaft to restrict inlet
• Accepts larger feed stock
• High speed grinding action, ideal for dry granulation
Top driven direct drive
• An alternative for ‘hopper feed’
installations
• Compact
• High torque, slow speed applications
Top driven module
• Bare shaft
• For connection to customers’
power units
• Ideal for fitting directly to the
outlet of a drier
In-line under-driven direct drive
• No drive shaft to restrict inlet
• Accepts larger feed stock
• Slower speed grinding action, ideal for
wet granulation
THE RANGE CONTINUED
Remote location in-line under-drivendirect drive
• As in-line under-driven direct drive, except that the
drive is located separately from the milling chamber
• Ideal for clean room operation
• A practical solution for explosive environments
Again through our extensive applications experience,
we have developed some key construction options
to satisfy individual process, operational, cleaning
and installation requirements. We are always willingto develop our Cone Mills further in pursuance of our
customers’ operational challenges.
Customising options - Milling Chamber Housing
In addition, we offer KEK Cone Mills for
hazardous area operations which include:-
• Flameproof electrics
• Hydraulic drives
• None-sparking materials of construction
• Inert gas purging
Swing away dischargechute
• Top drives only
• Easy cleaning
• Rapid cone changes
• Easy rotor clearance adjustment
• Ideal for mobile machines and
bagging-off applications
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cone mills
kemutecSpecialists in Powder Processing Technology
Side access discharge chute
• Hinged or removable access door on discharge
chute
• Discharge chute is accessible for easy cleaning
• The cone can be easily removed or replaced
• The rotor is easily accessible for adjustment
• Ideal for fixed or in-line installations
Mast mounted Cone Mills
• Cone Mill can be swung off-line to the side
• Facilitates raising or lowering for cleaning or
grinding media changes
• Enables Cone Mill to be replaced by a make-up
piece when product does not require processing
Hinged orremovable
access door
In addition, our comprehensive range can readily
accommodate any of the following process
requirements:-
• Fully mobile Cone Mills
• Explosion containment up to 10 bar
• Explosion suppression systems
• Fully flushable CIP
• Spray ball CIP
In-lineprocess
Pull through Cone Mills
• In-line vacuum conveying systems
• Continuous dust-tight operation
• Less risk of contamination
Rise andfall mast
Rotatablemast
APPLICATIONS
Granulationa. Pharmaceutical Wet Granulation
To process ‘wet mass’ product from a High SpeedMixer and produce small ‘nodules’ with a large surfacearea to weight ratio to maximise the efficiency of theonward drying process
Kek in-line Cone Mill with under-driven grinding media
• Full bore opening provides no restriction to incomingproduct
• Sealed gearbox providing hygienic, slow speed drive– ideal for the wet granulation process
The need
The solution
The benefits
The need
The solution
The benefits
To grind or ‘granulate’ product after the drying process(see ‘Wet Granulation’ above). Prior to tableting
Kek belt drive Cone Mill with over-driven grinding media
• High speed grinding through belt drive to providehigh impact milling action
• Sealed ‘drop through’ installation – ideal forenclosure within a downflow booth
• Ideal for mobile machines and bagging-offinstallations
b. Pharmaceutical Dry Granulation
High shearmixer
Kek in-line Cone Mill (direct under-driven) – slow speed in-line process
Move IBC to drier feed
Collect in IBC
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cone mills
kemutecSpecialists in Powder Processing Technology
Inflatable seal
The need
The solution
The benefits
To grind reject or scrap product and to recycle back intothe original process as a small percentage of the totalvolume, or to produce material which is the basis of aproduct in its own right
Kek belt drive Cone Mill with over-driven grinding media
•In-line dust free operation •Low energy, short residence time Cone Mill action
ensures minimal heat transfer into product obviatingfat melt
•Fine ground product achieved in one pass and idealfor adding back to the original process
Typical bakery/confectionery re-work applications:-• Cream biscuits• Agglomerated boiled sweets• Chocolate bars• Bread crumbing• Rusk milling• Biscuit grinding for dessert bases
Kek belt driveCone Mill – high
speed dropthrough process
Downflowbooth
Drumcollection
Fluid beddrier
Biscuit and confectionery re-work
c. Other granulation applications• Detergent ingredients and tablets• Babyfood flakes• Spice de-agglomeration• Graphite• Sugar grinding• Brown (demerera) sugar de-agglomeration
Ground biscuit
Other applications
• Pharmaceutical tablet reclaim• Detergent tablet reclaim• Mint crystal grinding• Milk powder de-agglomeration
Hand tip biscuits
Adjustable gate
Belt conveyorKek belt drive Cone Mill
Mobile bin
Ground biscuit
KEMUTEC
Kemutec
Kemutec is well established as a leadingmanufacturer of dry bulk solids processing andhandling equipment of outstanding quality. Ourspecialist technologies are particularly suited toapplications in the food, pharmaceuticals, plastics
and chemicals industries. Besides cone milling, theyinclude other size reduction techniques, mixing/blending, sifting and solids flow control.
Partnership with customers and emphasis on service are the corner-stones of our success. Ourengineers work directly with customers to design andbuild equipment for specific applications each basedon proven experience in the technologies in whichwe excel.
We have modern, purpose built ISO 9001 accreditedmanufacturing facilities. We place particular
emphasis on surface finishing, whatever the material.Mirror polishing of crack and crevice free equipmentconstructed from stainless steel is a particularspeciality, reflecting our commitment to excellenceacross the full product range.
Packaged engineering
In addition to the manufacture of individual machines,
our extensive experience makes us well placed to
design, manufacture, install and commission
processing packages including the associated
pneumatic (or other) conveying systems, support
structures and controls.
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cone mills
kemutecSpecialists in Powder Processing Technology
Technology Centre
Our policy is to ensure that our customers have the
best opportunity to test our equipment in a location
and framework which enables them to make a
realistic assessment of its suitability for their
particular needs.
Accordingly, we operate two comprehensively
equipped ‘technology centres’ one of which is
located at our UK headquarters and the other at our
North American base in Bristol, Pennsylvania where
trials on customers’ materials can be carried out with
a representative from the customer in attendance or
not, as the customer chooses.
Both sites are equipped with both production and
pilot size Cone Mills where short to medium duration
tests can be carried out in a controlled environment
which allows full characterisation and recording of
the trial results.
Hire facilities
As an alternative to trials within our technology
center we are able to undertake trials at customers’
premises. This is particularly desirable where the size
reduction process needs to take place while the
product is in a specific condition or where it is of a
nature requiring a high degree of containment. We
offer test units complete with a full range of cones
and beater options. Each machine has an electronic
variable speed control with speed indication. To
complete the monitoring program, we provide
load meters and hours run indicators too. Trials
machines are available to meet the European and
North American standards for operation in hazardous
environments where solvents or explosive powders
may be present.
After Sales Service
At Kemutec, we believe that the trials and delivery of
equipment are just the beginnings of what will
become a long term relationship. To ensure the
smooth operation of our customers’ production, not
only is our equipment robustly designed for longevity
but we offer planned maintenance schedules and
hold a comprehensive stock of wear parts and other
key components.
Kemutec130 Wharton RoadBristol, PA 19007Telephone:215 788 8013E-mail:[email protected]
Website:www.KemutecUSA.com
Kemutec has its own sales office in the USA and has a comprehensive network of representatives throughout theindustrialised world, all able to provide applications engineering, sales and service.
OUR OTHER PRODUCTS
GARDNER MIXERS & BLENDERSWe offer an extensive range comprising laboratory
mixers, ribbon mixers, ploughshare mixers,
continuous mixers, reactors, processors, double
cone blenders and drum blenders.
KEK CENTRIFUGAL SIFTERSCompact, high efficiency sifters for throughputs up
to 100 tph. Most have cantilevered drive shafts
reducing the number of bearings and seals - offering
major benefits for hygiene and cleaning.
KEK KIBBLERSDesigned to accept lumps up to 150mm dia. and
reduce them down to 2 or 3 mm within a narrow
particle size distribution and with minimal fines at
rates ranging from 2 to 25 tonnes/hour.
Our skilled and experienced, professional engineeringstaff are well qualified to discuss, analyse, evaluateand produce a cost effective solution to meet yourpowder processing and handling requirements.
Talk to us, to find out how we can help you to achievegreater productivity, new processes and increasedprofitability.
KEK UNIVERSAL MILLSFor the fine grinding of food, pharmaceutical and
chemical materials of up to 3 Moh hardness to within
the range of 30 to 500 micron mean particle size.
Kemutec Also Supplies:Ø Kek Centrifugal SiftersØ GKM Tumbler ScreenersØ Kek Univesal MillsØ Kek Cone MillsØ Kek Kibbler Lump BreakersØ PPS Air Classifier MillsØ Gardner Mixers and BlendersØ Mucon Valves and Discharge Aidskemutec
Specialists in Powder Processing Technology