Processing February 2012

S O L U T I O N S F O R T H E P R O C E S S I N D U S T R I E S

February 2012

Work Light Strip

The WLS28 delivers a versatile lighting

solution, featuring a robust, yet small profile,

metal housing and is available in various lengths

from 145mm to 1130mm, while maintaining

the same narrow width of 28mm for all models.

Extremely bright LEDs emit an even pattern of

light, casting no shadows. The WLS28 also

provides significant cost- and time-

saving attributes in the

form of energy effi-

ciency and installa-

tion simplicity. For

more informa-

tion about Plant

Maintenance

& Safety, go to

page 32.

Banner Engineeringwww.bannerengineering.comWrite In 503

Rotary Feeder for Bulk Material Handling

The MD Series of rotary feeder valves from ACS Valves immediately con-

tributes tangible operating efficiency advantages and

long-term production and maintenance savings. It

is constructed with an 8-vane rotary valve that

ensures proper pressure sealing at the inlet

and outlet flange. The optimal seal pro-

duced by an MD Series rotary feeder can

reduce compressed air loss by up to 28 CFM/year,

according to the manufacturer. For more informa-

tion on Powder & Bulk Solids, turn to page 38.

ACS Valveswww.acsvalves.comWrite In 502

Mixing and Dispersing Batching System

The “Standard Production Plant” (SPP) is a multi-purpose mixing

and dispersing batching system designed to emulsify, homog-

enize or blend virtually any material. The vessel, recirculation

piping, valves, controls and dual in-line mixing unit are

included. Design of the SPP eliminates the need for

additional equipment such as circulating and transfer

pumps. Two components in the system — an integral

agitator and high-shear mixing unit — combine to pro-

vide the most complete mixing, with the option to add

powders without the need of vacuum. The SPP construc-

tion is limited to features necessary for the process as it

relates to mixing results. For more information on Mixing

& Size Reduction, go to page 8.

IKA® Works, Inc.800-733-3037, www.ikausa.comWrite In 500

Biosphere Industries, a manufacturer of biodegradable

packaging and biodegradable bakeware, needed a highly

accurate ingredient batching system to help meet its

sustainability goals. The company interviewed several can-

didate vendors and, on the basis of speed, repeatability,

lead time for completion and cost, selected a turnkey

automated batching system. To read about this success

story, turn to page 20.

Try as we might, instead of improving communica-tion, contemporary society still seems compelled to make it more difficult. The use of buzz words, acronyms and other letter abbreviations is increas-ing at a dramatic pace. Frequently, the creation of a new series of acronyms or other letter-type abbreviations is simply an attempt to make a con-cept appear substantially different from previously known data, when in fact, it’s the same old stuff

with a different name. Pump expert Ross Mackay discusses effec-tive communication in this exclusive guest column. To read the column, turn to page 18.

www.ProcessingMagazine.com

Next Generation Slurry PumpThe new Goulds XHD Extra Heavy Duty World-Class Lined Slurry Pump

can handle the heaviest slurry under the toughest conditions, according

to the manufacturer. The new pump is designed to

be maintained even while running, and to require less

downtime for service procedures — with parts that

are more accessible and adjustable than in other

slurry pumps. For more information on Pumps

& Seals, go to page 14.

ITT Gouldswww.gouldspumps.comWrite In 501

Featured Article

Featured ColumnistMixing & Size Reduction

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Table of Contents2

MAKE: An American Manufacturing MovementThe Council on Competitiveness, a Washington, D.C.-based non-profit, non-partisan organization, is seeking to re-establish manu-facturing as a cornerstone of American independence.

Horizontally-Split Centrifugal Compressor ConfigurationRotating equipment engineer Amin Almasi addresses the optimal configuration for horizontally-split centrifugal compressors.

Sustainable Food Packaging SolutionsA manufacturer of biodegradable packaging and bakeware selected a turnkey automated batching system for its speed, repeatability, lead time for completion and cost.

Better Safe Than Sorry!Based on the harmless appearance of a bagel, it’s hard to imagine that making these popular treats may, in fact, pose an occasional hazard. But it’s true, according to officials at a bread manufacturing company based in Toronto.

Getting Serious About LubricationDespite millions of dollars spent to improve machine condition and reliability, improper lubrication is still cited as the primary cause of premature equipment failure today.

The Importance of Thorough MixingGlass manufacturer utilizes an abrasion-resistant rotary mixer to blend ingredients rapidly.

Editor’s Column

Mixing & Size ReductionA technical resource for mixing and blending from Charles Ross & Son is featured.

Pumps & Seals

Food EquipmentSpear-tip piercing pH electrodes are among the spotlighted products in this section.

Plant Automation

Plant Maintenance & SafetyA line of industrial sounders from Pfannenberg is spotlighted.

Powder & Bulk Solids

Tanks & Vessels

Info Center

Classifieds

Index

12

6

4

38

43

44

14

8

28

29

32

20

February2012 • volume25,number02

February 2012•www.ProcessingMagazine.com

40

26

30

34

41

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February 2012 • www.ProcessingMagazine.com

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In his State of the Union address before Congress on Jan. 24, President Obama laid out a vision for revitalizing the American economy with an emphasis on U.S. manufacturing.

In particular, the president said he wants to implement a minimum tax for multinational com-panies, which would help provide tax breaks for companies that create jobs in the U.S. He sweet-ened the pot by calling for bigger tax breaks for high-tech manufacturers and financial assistance for companies that choose to relocate to strug-gling communities.

“My message is simple,” Obama said. “It’s time to stop rewarding businesses that ship jobs overseas, and start rewarding companies that create jobs right here in America.”

The president also announced the creation of a Trade Enforcement Unit, which is tasked with making sure that no foreign company has an unfair advantage over U.S. manufacturers, and encouraged private sector companies to partner with community colleges to train new workers.

Of course, this was not the first time Obama has campaigned for American manufactur-ing. Two weeks prior to the State of the Union, Obama hosted a forum at the White House to discuss the trend of “insourcing.”

During the “Insourcing American Jobs” forum, the president met with leaders from 14 companies — including Ford, Dupont, Intel and Siemens — to lay out his plan for increasing

investment in the United States and to learn what incentives corporations would need to bring jobs back to this country.

“I don’t want America to be a nation that’s primarily known for financial speculation and racking up debt buying stuff from other nations,” Obama said. “I want us to be known for making and selling products all over the world stamped with three proud words: ‘Made in America.’ And we can make that happen.”

While Obama’s interest in re-establishing the U.S. as a manufacturing superpower is refresh-ing, it remains to be seen whether the president is serious about enacting these reforms or if he is simply pandering to blue collar Democrats. Unfortunately, the chances of getting any major legislative initiatives passed before the November election are slim at best.

What do you think about the president’s proposals to invest in American manufacturing? How will it affect your business? Send me your thoughts at [email protected].

Editor’s Desk4

Bringing U.S. Manufacturing Back: A Blueprint for the Future?

Reader Advisory Board

• RobertJ.Bockserman,President, Conatech

• PeterS.Cartwright,President,

Cartwright Consulting Co.

• BarryCharnay,President & CEO, Whisper

Ingredients Inc.

• KenDelafrange,President, Jadee Inc.

• DonGraham,President, Graham Sanitary

Design Consulting, Ltd.

• StanleyHerzog,President, Princeton

Process Technology Consultants

• B.GeorgeKniazewyz,President, Renovare

• EricLanger,President, BioPlan Associates

• EdMarshall,President, Maintenance

Management Technologies

• DaveC.Orlowski,President & CEO,

INPRO/SEAL Company

• JohnStansield,Plant Manager,

Accelerated Curing Inc.

• Dr.JesseYoder,President, Flow Research

—NickPhillips,Managing Editor

[email protected]

Follow me on Twitter @ ProcessingMag

Publisher, Mike Wasson

Ph: 973-539-7715, Email: [email protected]

Managing Editor, Nick Phillips

Email: [email protected]

Associate/Web Editor, ChristyUnderwoodEmail: [email protected]

Art Director, JamesArmstrongEmail: [email protected]

Graphic Designer, Brandon Watkins


Marketing Manager, Mary Beth Timmerman


Advertising Sales Assistant, HaleyMartinEmail: [email protected]

Administrative Team:

General Manager, BarryLovetteVice President of Operations, BrentKizzireVice President of Marketing, HankBrownVice President of Finance, BradYoungbloodDirector of Circulation & Fulfillment, Delicia Poole

Circulation Manager, Electronic Products, StacieTubb

PROCESSING (Pub.#ISSN 0896-8659)

PROCESSING Magazine is published monthly by Grand View Media Group. Editorial

and Executive Ofices: 200 Croft Street, Ste 1, Birmingham, AL 35242. Periodicals post-age paid at Birmingham, AL & additional mailing ofices. Canada Post: Publications Mail Agreement #40612608. Canadian Returns to be sent to: Bleuchip International, P.O. Box 25542, London, ON N6C 6B2. POSTMASTER: Send address changes to PROCESSING Magazine, PO BOX 2174, Skokie, IL 60076-7874. SUBSCRIPTIONS: Non-qualiied domestic subscriptions: one year, $57; two year, $99; single issue, $10. Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail subscription: one year, $203; two year, $355. © Grand View Media Group, 2012. PROCESSING Magazine assumes no responsibility for validity of claims in items reports.

ForSubscriptionQuestions/Inquiries:U.S. – 866-721-4807 Outside U.S. – 847-763-1867E-mail – [email protected] / Renew / Change of Address:www.processingmagazine.com/subscribe

S O L U T I O N S F O R T H E P R O C E S S I N D U S T R I E S

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The Council on Competitiveness, a Washington, D.C.-based non-profit, non-partisan organization, recently celebrated its 25th anni-versary during the National Manufacturing Competitiveness Summit on Dec. 7-8, 2011. The Council, whose membership consists exclusively of corporate CEOs, presidents of universities and heads of labor unions, provides policy recommendations to make America more competitive in the international marketplace.

Under the leadership of Council President and CEO Deborah L. Wince-Smith, Council Chairman and Deere & Company Chairman and CEO Samuel Allen and a steering committee of 60 CEOs, university presidents, labor leaders and laboratory directors, MAKE: An American Manufacturing Movement was released to Congress, the White House and all 50 governors on Dec. 8, 2011. Outlining the ways in which the U.S. can maintain and grow the domestic manufacturing base, the rec-ommendations are the result of hundreds of interviews conducted over nearly three years by Deloitte, as well as dozens of dialogues where Council members and national leaders came together to discuss specific manufacturing topics.

MAKE argues that manufacturing is a cornerstone of American inde-pendence, economic prosperity and national security that must not be surrendered. Americans can no longer afford to allow their formidable innovation and creativity machine to fuel production in other countries and must capture a greater share of the benefits of American ingenuity. Our national economic portfolio requires a healthy and growing manu-facturing sector to meet the grand macro-economic problems we face.

The image of manufacturing as “dumb, dirty, dangerous and disap-pearing” is far from accurate. Today, manufacturing is smart, safe, sus-tainable and surging.

The key challenges and solutions outlined in MAKE include:1. Challenge: Fueling Investments in the Innovation and Production Economy from Start-up to Scale-upSolution: Enact fiscal reform, transform tax laws, regulations and other structural costs to spur investment, ramp up production, capitalize growth companies and create skilled jobs.2. Challenge: Expanding U.S. Exports, Reducing the Trade Deficit, Increasing Market Access and Responding to Foreign Governments Protecting Domestic ProducersSolution: Create fair and open global markets for U.S. goods and services to reduce the trade deficit and increase exports as a percentage of GDP.3. Challenge: Harnessing the Power and Potential of American Talent to Win the Future Skills RaceSolution: Prepare the next generation of innovators, researchers and highly-skilled workers.4. Challenge: Transforming the Industrial Base to Smart Manufacturing and Innovation Networks to Spur Next-Generation ProductivitySolution: Create national advanced manufacturing networks and partner-ships, prioritize R&D investments and deploy new tools, technologies and facilities.5. Challenge: Optimizing and Integrating Next Generation Supply Networks with Advanced LogisticsSolution: Develop and deploy smart, sustainable and resilient energy, transportation, production and cyber infrastructures.

MAKE is available for free download at the Council’s website at www.compete.org.

MAKE: An American Manufacturing Movement

Non-Proit Organization Seeks to Re-establish Manufacturing

as a Cornerstone of American Independence

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8 Mixing & Size ReductionAutomated Bulk Material Mixing SystemDesigned specifically for fully automated introduction, transfer, mixing and blending of multiple, sluggish materials, this NBE inte-grated mixing system produces such homog-enous blends that downstream production scrap is virtually eliminated, according to the manufacturer. An NBE lift-and-seal gaylord discharge system, with a dust-tight, custom

discharge hood, introduces the material to the transfer bin. An integrated agitator and vacuum pump transfer system supply material to the high-volume material mixer. Within the mixer, an auger mixes material in a 10-gauge mix tube. In-feed

scoop blades at the base of the mixing auger, and broad-throw dispersion paddles at the top ensure a homogenous and consistent blend supply to downstream processes.

National Bulk Equipment Inc.www.nbe-inc.com

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Multi-Cage MillThe Stedman “H” Series™ Multi-Cage Mill is available in 2:4- or 6-row design and in four sizes up to 250 TPH. The design features also include Air Cannons,

Heaters and Hydraulic Ram. The Air Cannons are mounted at the intake and discharge to help prevent build-up of wet sticky material, while the heaters are also installed on the grinder housing to retard buildup of wet mate-rial. The Hydraulic Ram eliminated the gear head motor and rack & pinion that were used on other Stedman cage mills, now costing less to maintain, according to the manufacturer. The cage mill is a selective crushing, con-trolled-impact, multi-cage mill designed for siz-ing minerals and agglomerates, whole grains, chemical, ores and many other materials.

Stedmanwww.stedman-machine.com

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Technical Resource for Mixing and BlendingProcess engineers and R&D scientists have a new technical resource for their mixing and blending related questions at the Charles

Ross & Son Company web-site.The Ross “Mixing Technology Insights” pro-vide many use-ful tips and

techniques on dispersion, dry blending, emulsification, homogenization, particle size reduction, high viscosity mixing, sub-surface powder induction, sanitary mixing and other topics. Each two-page bulletin includes a sample application or mixer installation from various industries.

Charles Ross & Son Companywww.mixers.com/insights-new.asp

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10 Mixing & Size ReductionUpgraded Mixer Gears Deliver Quieter OperationNeptune Mixer Company, a division of the Neptune™ Chemical Pump Co., has made a commitment to providing mixers that offer the longest

service life when compared to competitive brands, accord-ing to the manufacturer. This longevity is designed into the product through the use of steel helical gears, high-quality bearings and high-grade lubricant. Recent feedback from

customers highlighted an opportunity for Neptune to reduce the perceived sound levels being emit-ted from the gear-train on several of its mixer lines.

Neptune worked closely with its gear supplier to opti-mize the gear-tooth profile by increasing the American Gear Manufacturers Association (AGMA) Quality Class from a level 6 to a level 9, resulting in tighter manufacturing tolerances on the mesh and backlash, as well as an improved running-surface fin-ish. This upgraded, quieter gear operation was incorporated on Neptune mixers that went to market in September 2011.

Neptune Mixer Companywww.neptune1.com

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Impeller Designed to Prevent Fibrous Material BuildupThe new Chemineer® RL-3™ impeller is designed to prevent fibrous material buildup on the rotating impeller of agitators. In blending and solids suspen-

sion applications where the fluid contains fibrous material, the resulting buildup on the agitator’s impeller can deteriorate performance. The Chemineer RL-3 Ragless Impeller prevents buildup to eliminate mainte-nance costs and downtime, increase performance and extend the ser-vice life of the agitator, according to the manufacturer.

Chemineerwww.chemineer.com

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Variable Flow Static MixerThe Westfall Model 2900 Variable Flow Static Mixer optimizes mixing and minimizes head loss by employing two in-line wafer-

type mixers, one fixed and one variable, which adjust incrementally to maintain con-stant head loss. Providing consistent mix-ing over a 20:1 turndown ratio, this mixer reduces overall system head loss at high flow rates and permits the use of smaller pumps, according to the manufacturer. Saving energy and pump wear-and-tear, the Westfall Model 2900 Variable Flow Static Mixer is available in

sizes from 3/8-inch to 120-inch I.D. Separated by a distance equal to two pipe diameters; as the flow velocity increases, the variable mixer opens to reduce excessive head loss. The fixed mixer has a 0.9 Beta ratio and the variable mixer has a 0.7 Beta ratio.

Westfall Manufacturing Companywww.westfallmfg.com

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12Compressors

Centrifugal compressors do not exhibit the internally induced shaking forces and complex pul-

sation problems of reciprocating compressors, and therefore do not need the same massive foundation and valve (or unloader) repairs.

As plant sizes increase, the pressure to improve reliability is very high because of the large economic impact of a nonscheduled shutdown. In many modern process plants, nonscheduled shutdown impact is comparable to the long-term impact of a small decrease in efficiency. Run time between centrifugal com-pressor overhauls currently is around four years or more. Six year run times are not unusual, and eight years or more are also reported.

Centrifugal compressors, because of their simplicity, reliability, light-weight and compact design, have become much more popular for use in process plants.

Centrifugal compressors have been applied in an approximate range of 2000 m3/h to 400,000 m3/h. Centrifugal compressors are available somewhat outside this range, but have problems competing because other more efficient compressors are available for above and below this range.

Compressor ConfigurationFor low- and medium-pressure applica-

tions, horizontally-split casings are common. Maintenance of a horizontally-split compressor is very simple and straightforward as the rotor is removed without disturbing the impellers.

Horizontally-split casing major maintenance is much simpler with downward piping connec-tions because there is no need to disturb the pipework when opening the casing. Inter- and after- coolers, as well as other auxiliaries (such as vacuum condensers for steam turbine driv-ers), can be conveniently located below the operating floor. As an indication, a horizontally-split compressor is applied below around 40 Barg. However, this limit depends also on flow and gas compositions. For high capac-ity machines, a horizontally-split compressor is used for below 25 Barg.

The pipe loads imposed on a casing should be limited. API 617 specifies nozzle load lim-its around 1.85 times NEMA SM23. However, some purchasers ask for higher loads, even as high as four times NEMA SM23, to make piping design easier. For some very large refrigeration compressors — due to very large piping seizes and considerable temperature differences — even five times NEMA SM23 may be specified. These high loads may not be recommended by some engineers and API values could usually be considered as optimum selection. Vendors generally design process compressor models

based on API. There is often doubt whether all necessary modifications will be implemented by vendors for higher piping load values (with respect to long-term component life expected). But in some projects there is no way to ensure proper piping design and avoid expansion joints except by using higher nozzle load limits.

When applications are more complex than can be accommodated by a single-case com-pressor, multiple cases can be used. A popu-lar configuration is the tandem-driven series arrangement using a common driver. Gear units may be included in the compressor train, either between cases or between the driver and the compressors.

The maximum number of compressor casings is usually limited to three. Longer, tandem-driven series connected compressor trains tend to encounter specific speed problems. In the longer trains, the double flow arrangement can be useful (for the first stage) in permitting more casings to run at the same speed. At the inlet, where flow is highest, the gas stream is divided into parallel streams and the volume is reduced to a value within the specific speed capability of a single flow compressor. The alternative is the use of a speed increasing gear unit between compressor bodies to permit the flow match-ing of down-stream stages. When longer trains are needed, the cases are grouped with several individual drivers, maintaining the series flow concept.

Amin Almasi

Lead Rotating Equipment Engineer

at WorleyParsons


Horizontally-Split Centrifugal Compressor Configuration and Driver Selection


www.ProcessingMagazine.com • February 2012

13

Driver SelectionHistorically, the most popular drivers for centrifugal compressors have

been steam turbines, which are still common drivers of centrifugal com-pressors in some process plants. Generally standard, compact and reli-able steam turbine designs are available with reasonable cost for mechan-ical drives.

Electric motor drives, with the exception of very large units with high inlet flows, require that a step-up gear is used. Because fossil fuel can be more efficiently converted to electricity in large central generating sta-tions, the costs of electrical energy for motors become such that to dis-place the more convenient steam turbines. The electric motor received a high degree of attention in modern process plants. Large electric drivers using variable frequency conversion are very popular. Initial cost may be prevented with universal acceptance of the variable frequency. However, it is a common solution for medium and large machines. Electric motors, whether speed-controlled or not, are either induction or synchronous in design. Size and plant electric system requirements set parameters for motor selection. Synchronous motors normally receive consideration only for the large drivers, with the individual plant setting the minimum size at which the synchronous machine is used. Motor drives shall conform to proper standards such as API 541 or API 546, as applicable (or for small motor IEEE 841). For motors, special consideration shall be given to the starting conditions and effects of pulsating torque. Also interaction effects with the transmission system and gear unit when variable frequency drive motors used are important.

A gas turbine is selected as a compressor driver based on available fuel

and plant specific requirements. It should be understood that gas turbines are relatively standardized even though they cover a wide range of power and speed. They are not custom engineered to the specific application for a power and speed match. The speeds of gas turbines are standard for a given frame. Sometimes the output speed of the gas turbine can be considered to design an efficient compressor. If not, an intermediate gear will be needed. It adds the complication of another piece of equipment, subsequently higher capital cost and potential decreased reliability. This gear unit also inherently has a high pitch line velocity making for one of the difficult applications. If exhaust heat recovery or regeneration is used, the efficiency of the gas turbine is quite attractive.

Drivers generally should be sized to deliver continuously not less than 110 percent of the maximum power required by the centrifugal compres-sor. Sometimes this margin may increase to 15 percent.

Advanced technologies have been used to provide maintainable, flex-ible and compact process horizontally-split centrifugal compressors. Worldwide installed capacity and horsepower of centrifugal compres-sors in process industries are more than other compressor types. Well-designed centrifugal compressors have a high reliability and they are favorites to install without spare.

Amin Almasi is lead rotating equipment engineer at WorleyParsons, Brisbane, Australia. He specializes in rotating machines including centrifu-gal, screw and reciprocating compressors, gas turbines, steam turbines, engines, pumps, subsea, offshore rotating machines, LNG units, condition monitoring and reliability.

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14 Pumps & Seals

Customized Solution for Exothermic ReactionsKNF N0150 diaphragm pumps can now be customized with water-cooled heads to prevent pump overheating in process applications where exo-thermic reactions from helium, xenon

and other gases may produce excessive heat and potentially shorten pump service life. This powerful pump

is designed to deliver the highest flow rate of any electrically-operated diaphragm pump, according to the manufacturer. The pump operates without oil to eliminate risk of medium contamination and can be equipped with a double-diaphragm system for increased safety, which is critical when handling particularly dangerous gases.

KNF Neuberger Inc.www.KNFprocess.com

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Sanitary PumpsMoyno® Sanitary Pumps are ideal for any application where bacteria and contamination must be avoided and/or frequent clean-up is required, according to the manufacturer. Featuring standard mechanical seals, all 150 standard models meet 3A sanitary requirements with no modifications necessary. In addition, a combination close-coupled/open throat design is offered in a standard model.

Moyno, Inc.www.moyno.com

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Air-Operated Double-Diaphragm Pump TechnologyWilden’s Advanced™ Series Metal Air-Operated Double-Diaphragm (AODD)

Pump technology features the operational advan-

tages necessary to over-come the challenges in the ever-evolving,

oftentimes difficult oper-ating conditions found

in paint and coatings manufacture. Wilden’s

Advanced Series pumps possess the versatility that

allows them to be used at every stage of the paint-and-coatings production process, from raw-ingredient transfer to mixing, batching and filling.

Wilden Pump & Engineering Companywww.wildenpump.com

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16 Pumps & Seals

Pump for Lime Slurry ApplicationsThe Bredel SPX reliably handles a vari-ety of harsh materials, such as abrasive lime slurries. Advanced peristaltic tech-nology enables the SPX to pump abra-sive and corrosive chemicals depend-ably for a long period of time. The precision-machined hose is designed for long-life even when pumping slur-ries that cause other pumps to fail. With flow-rates up to 350 GPM and pressures up to 232 PSI the Bredel SPX hose pump is designed for continuous duty under the most difficult applica-tion conditions.

Watson-Marlow Pumps Groupwww.wmpg.com

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O-Ring Calculator AppTrelleborg Sealing Solutions (TREL-B) has announced the release of the “O-Ring Calculator” app. The new app calculates O-Ring dimensions and tolerances and recommends sizes and Trelleborg Sealing Solutions part numbers. This new app joins the success-ful “ISO Fits & Tolerances” and “Unit and Hardness Converter.” All are available in English or German, free from iTunes® or via the Apple App Store on the iPhone and iPod Touch.

Trelleborg Sealing Solutionswww.tss.trelleborg.com

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Chemical Dry Vacuum PumpsEdwards has launched a new range of dry pumps that delivers exceptional vac-uum performance in harsh chemical, pet-rochemical and pharmaceutical process-es. The easy-to-use CXS pumps feature cutting-edge tapered-screw technology; have excellent reliability; are simple to

install; envi-ronmentally-friendly; and give improved liquid and sol-ids handling, according to the manu-facturer. As a result, they are economic

to run and users can optimize their vacu-um processes and minimize overall cost of ownership.

Edwardswww.edwardsvacuum.com

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18 Pumps & Seals

“I know you believe you understand what you think I said, but I am not sure you realize that what you heard is not what I meant.”

The main problem arises if you can make any sense at all of the opening sentence, but it exemplifies the most prevalent problem in the pump business today: effective communication.

It finally happened! I could see it com-ing from the increasing dependency on buzz words, acronyms and letter abbreviations by so many who make presentations in our industry.

I attended a workshop where I hardly under-stood a word that was being said.

OK, maybe I’m exaggerating a bit. After all, I knew the speaker was discussing how to improve system reliability, but I really did not understand the key points that were being made.

On too many occasions during the presenta-tion, I found myself on the receiving end of a barrage of words that were not even English. All the keywords were in Greek. The speaker actually was using the Greek language for ter-minology that could just as easily have been defined in English. The classic phrase was: “If we increase the Beta, then the Omega will be improved at the same time.” This statement was made with no subsequent explanation of either Beta or Omega.

Let’s get serious! The English language has enough confusion built in — let’s not add to it.

Effective communication is essential to good business, so why do we need to introduce a second language?

It’s worth remembering that the first rule of communication is that it is the speaker’s responsibility to ensure that the message he or she is attempting to deliver is received as it was meant to be received. The onus of under-standing is not on the recipient. In other words, if there is something in this article you don’t understand, then the fault is mine — not yours.

Most people would consider the number one problem of communication to be that it does not happen. Such is not the case.

Try as we might, instead of improving com-munication, contemporary society still seems compelled to make it more difficult. The use of buzz words, acronyms and other letter abbre-viations is increasing at a dramatic pace.

We in the pump business have long been familiar with the terms “BEP” and “TDH.” Some years ago, we started discuss-ing “MTBF,” until someone decided they didn’t like the implication and changed it to “MTBR.” Is there really a difference between the Mean Time Between Failure and the Mean Time Between Repair? Besides, it’s been almost 20 years since the initial concept was discussed, and we are still arguing about what it means and how to measure it. These were the same problems we had before the term(s) was introduced.

Frequently, the creation of a new series of acronyms or other letter-type abbreviations is simply an attempt to make a concept appear substantially different from previously known data, when in fact, it’s the same old stuff with a different name. The only reason for it to be given a different name is so that the individual who thought it up might be considered unique. For example, I recently read about “LOD” and “ROD” in a discussion of a pump curve. As it turns out, the author was simply referring to the position of the actual operating point as being to the Left or Right of the Design Point. He could have said so quite plainly without resorting to the undefined acronyms.

So, if we implement Lean Six Sigma to achieve the lowest MTBF, we may have to get the IT people to utilize an EAM/CMMS with RCM and hire a CMRP to introduce PM proce-dures ASAP! Better yet, why don’t we just do what’s required to stop the frequent and repet-itive pump failure? Then, let’s do lunch at KFC.

And people ask me why I also teach Presentation Skills!

Ross Mackay specializes in helping companies increase their pump reliability and reduce oper-ating and maintenance costs through pump training programs. Working out of Aurora, Ontario, he is the author of “The Practical Pumping Handbook” and can be reached at 1-800-465-6260 or through his website, www.practicalpumping.com.

Ross Mackay

Ross Mackay Associates Ltd.


Effective Communication in the Pump Business


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Biosphere Industries was founded in 2002. Its mission, according to founder Elie Helou Jr., is reflected in its name. “Biosphere sought to provide closed-loop food packaging systems that have minimal to no impact on the earth’s natural life cycles,” he explains. “Using yearly renewable raw materials, and ultra-efficient (essentially no-waste) manu-facturing processes, we wanted to deliver truly earth-friendly solutions.”

Helou is an aeronautical engineer and a recognized expert in compos-ites technology. A major priority was using yearly grown raw materials that would have minimal impact on the environment. Other priorities related to defining the material. “We wanted to create a material that was primarily starch-based,” he explains. “Tapioca was chosen due to it allergen-free nature — some people are allergic to other starches, such as potato. We wanted it to be harvestable without killing the plant, so the supply would be annually renewable. We wanted it to be rigid, too — and have insulating properties so it could be a replacement for EPS or Styrofoam.”

Five years into the development effort, Biosphere introduced an

entirely new technology, in terms of both its composition and its pro-cess, for sustainable single-use food packaging that met all of these requirements — and more. Now marketed under the trade names Biosphere Bakeware and Blueware Serveware, it is unique in its approach: Rather than convert starch into plastic, the Biosphere process “bakes” the starch in a process similar to the baking of bread or muf-fins (ironically, two of the product categories that benefit most from the technology — more on that later.)

Ingredients in Biosphere’s unique “platform” technology include tapi-oca starch as the primary ingredient and a lesser amount of grass fibers and additives custom to each recipe that add strength, flexibility or color. The most critical aspect of the manufacturing process is ingredient batching, which must be highly accurate.

“The accuracy requirement was the spec most off-putting for vendors when we looked for a system,” offers Helou. “Our goal was to combine high output, which we expected to accelerate over time, with ingredient accuracy that would never deviate more than 0.5 percent.”

Sustainable FoodPackaging Solutions

Turnkey Automated Batching System Helps Company Reach Sustainability Goals

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Helou and his engineering team interviewed several candidate ven-dors and, on the basis of speed, repeatability, lead time for completion and cost, selected a turnkey automated batching system engineered and manufactured by Ingredient Masters Inc. of Cincinnati, Ohio.

The EquipmentThe first of the five modules is a super sack bulk handling system com-

prised of six 54 cu. ft. dispensing hoppers arranged in a single row. Each is equipped with pneumatic slide gate valves with dual dribble positions to optimize cycle times and discharge accuracy. Air-activated vibration at each hopper is controlled by a PLC to ensure consistent product flow. A robotic scale cart, also governed by the PLC, moves under the dis-

pensing hoppers and receives the precise amount of each ingredient specified in the recipe. The scale cart automati-cally docks with a transfer hopper to transport the ingredients. There are computer-con-trolled dust collec-tion points at each of the five hopper

discharge sites; dust collection can also be activated manually during hopper refilling.

The second module, a vacuum transfer system, is controlled by the central computer system. It automatically requests delivery of the next sequence of material whenever a premix hopper is empty. It has a pri-mary premix hopper mounted over the mixer that discharges through the mixer port, and a secondary premix hopper that discharges into the primary. A vacuum receiver mounted above the secondary hopper trans-ports ingredients sequentially from the scale cart transfer hopper into the secondary premix hopper.

Module 3 is a fiber handling system with a mechanically agitated hopper mounted on load cells. It functions as a “loss in weight” scale hopper and can also be filled from an existing fiber shredder discharge conveyor.

System control is provided by an Allen Bradley Compact Logix PLC running RSLogic 5000 for the PLC logic and RS view for operator graph-ics. A Dell Pentium computer runs Windows XP and RSLix provides PC to PC communication. A Microsoft access database stores recipe and ingredient information and records batch data.

The Process Powdered raw material (there is also a liquid component) for both

Biosphere product lines is received in 650 kg to 1000 kg “super sacks,” and subjected to full lab inspection using commercial bakery standards. Super sacks are installed on racks using a fork lift and frame, and con-tents are released into hoppers. When an order is received, the opera-tor creates a job order containing the recipe information, number of

22 Food Equipment

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batches to be run, and batch size. The computer confirms the availability of each dry ingredient and sends the job order information to the PLC. While the previous batch is mixing, the operator places a mixer bowl under the discharge of the first (fiber) hopper and initiates batching.

When all starting conditions (equipment positions, material availabil-ity) are met, a robotic cart moves to the station containing the filler and receives the discharge specified in the recipe. Ingredients are metered to a gain-in-weight type weigh scale — the type most often used in food

and pharma processing due to its higher accuracy and more manageable sanitation routine. When discharge is complete, the scale cart docks with the transfer hopper and sends the filler to the receiving hopper above the mixer, then through the secondary premix hopper, to the primary. The PLC then discharges the filler and meters liquid #1 into the mixer.

Following fiber transfer, the cart moves to the starch hopper, then on to the remaining ingredients — some of which are as fine as powdered sugar — with scent and colorant (if specified) as the final additions.

When each batch is complete, the system displays the recipe amount for each ingredient, along with actual amount discharged. The system is distinctive in that it supplies all of the required material to the mixer without delaying the mixing cycle.

The Ingredient Masters system main-tains a deductive inventory of the mate-rial in each dispensing hopper. When a discharge is made, the PLC deducts the amount from the available weight in the hopper. When a hopper is refilled, the operator enters the weight of the bulk bag into the computer and the PLC adds the weight to the available weight for the hopper. The discharge accuracy of the system for a 540-lb. batch is shown on the chart. The Ingredient Masters system can produce one batch every seven minutes.

Biosphere’s material has proven ideal as bakeware. Muffin trays and pie pans are excellent applications, as are bake-ware products with unique features, or deep draw requirements — the mate-rial will produce product with depths of 9-inches and greater.

The material has exceptional insula-tive properties, and adequate short-term moisture-resistant properties as well, so it’s a natural for ice cream. “Bakeware is where we started selling the technol-ogy,” says Helou, “because the material lets companies bake and sell in the same pan. The insulating properties are of great interest to the cold markets, such as smoothie and yogurt stores.”

The “yearly grown” 100 percent non-petroleum-based formula developed by Biosphere has proved well-suited to high volume production. At its Carpentaria, Calif.-development center, Biosphere has been able to test and fully develop this new technology. The company is evaluat-ing sites for a second production facility in the Midwest.

“Our goal,” says Helou, “is to source locally and use locally. We want to put farmers to work here, growing starch, bamboo and other ingredients, and avoid importing anything from abroad.”

Ingredient Masterswww.ingredientmasters.com

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24 Food Equipment

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Based on the harmless appearance of a bagel, it’s hard to imagine that making these popular treats may, in fact, pose an occasional hazard. But it’s true, according to officials at a Canadian bread manufacturing company based in Toronto, Ontario.

Used extensively in the bagel making process, highly pressurized hot water required during boiling offsets poten-tial quality problems. The process also requires a filtration system to clean raisins, sesame seeds, bits of dough, corn meal and other materials out of the hot water. And that’s where the danger can occur.

The company was using duplex bag filters for several years and was con-

cerned about employee safe-ty because of the hazards of manually changing filter bags while working with the high water temperatures.

ChallengesThe bread company

planned to install a new bagel boiler in its Alberta, Canada, plant,

which required a filter-ing system. Corn meal can create water quality problems if the temper-ature falls, requiring an

expensive and time- consuming water change. It is critical that the water in a bagel boiler remain at a high

temperature, even as it is filtered and recycled.

With employee safety in mind, the maintenance supervisor at the company’s Alberta plant wanted a filtering system that required less operator intervention than a bag system. High water tempera-tures used in the process can be a serious hazard to an operator changing filter bags, especially when pressed for time during the shutdown process when an operator may open up the filter hous-ing while it is still pressurized.

SolutionDecision-makers at the Alberta plant

wanted a filter they could count on,

BetterSafe Than Sorry!

Self-Cleaning Water Filters Help Bagel Maker Improve Safety

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Than Sorry!27


without the hazards occasionally associated with bag filter maintenance. Working with Eaton, the plant manager and maintenance supervisor determined that the Eaton DCF mechanically-cleaned filter was the per-manent solution to meet their business objectives.

The plant installed two Eaton DCF-800 filters on the boiler water recy-cle line at the Alberta facility. DCF filters successfully removed the raisins, sesame seeds, bits of dough and corn meal that would adversely affect the final product. Uninterrupted filtering by the DCF also ensured consis-tently high water temperatures required to maintain boiler water quality.

The DCF performs a self-cleaning action by mechanically scraping col-lected debris from the filter screen with a disc that travels up and down the screen, parallel to the liquid flow. The collection chamber at the bottom of the filter auto-matically purges collected debris without halting production, in a process that takes less than seven-tenths of a second. Because the DCF continuously cleans the screen without interrupting production, it maintains a consistently high flow rate and provides the highest quality filtering.

ResultsThe Alberta facility has eliminated the

risk of operator injury related to changing filter bags because there are no bags to remove and media cleaning is automatic.

The facility’s supervisors were also impressed with the unsurpassed filtering of its bagel boiler water and the ability to a maintain high water temperature while avoiding water quality problems.

Meanwhile, the plant is realizing finan-cial and environmental gains by eliminat-ing media, reducing worker exposure and reducing labor and disposal costs.

In fact, the company was so happy with the performance of the DCF filters at its Alberta plant, the Langley, British Columbia facility also installed DCF filters on its bagel boiler systems — instead of previously planned bags.

Eaton Corporationwww.eaton.com

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Water/Waste Processing,

a supplement to Processing magazine, helps connect you to the booming global

water and wastewater market.

And don’t miss WaterWaste.com, Processing’s new

website dedicated to water/wastewater

treatment.


Food Equipment

Metal Detectable Fluidizer DiskIn response to requests from food manufacturers who are look-ing for the highest purity for their product, Solimar Pneumatics has developed a metal detectable fluidizer disk. Solimar’s fluidizer disk mounts on the storage vessel wall and utilizes air pressure to unload

powder and bulk solids faster and completely without bridging and rat holing. The proven system is used for silos, hoppers and dry bulk trail-ers. Solimar’s silicone aerators have the highest manufacturing quality control and an excellent record of structural integrity, according to the manufacturer.

Solimar Pneumaticswww.solimarpneumatics.com

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Spear Tip Piercing pH ElectrodeFood industry process and plant engineers in

need of a durable, highly reliable penetration pH sen-sor for applications requiring sample piercing will find that

the S175CD Spear Tip Piercing pH Electrode from Sensorex is ideal for measuring the pH of semi-solid material samples such as meat, sausage and cheese. The S175CD’s pH electrode features an extremely rugged glass measuring spear-shaped tip, which is enclosed in a dura-ble, virtually unbreakable epoxy body. Its gel-filled, double-junction reference design provides protection from contaminating samples and provides extended service life if used with samples that interact with sil-ver ions. An extended surface area semi-porous PVDF (Kynar®) thermo-plastic provides the junction with excellent sample contact.

Sensorexwww.sensorex.com

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Forming MachineSpeed, product consistency and versatility are key to NuTEC Manufacturing’s 710 Forming Machine. The 710 provides excellent weight control and gentle product handling for a variety of products from beef to vegetables, according to the manufacturer. It can form hamburger patties, meatballs, skinless sausage links and many more items. The 710 Forming Machine operates with minimal wear and

maintenance. NuTEC supports the machine with factory direct service and a one year parts warranty.

Like all NuTEC equipment the 710 is opera-tor-friendly and easy to use.

NuTEC Manufacturingwww.nutecmfg.com

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28


29Plant AutomationFree Literature for AutomationFree literature from Omega Engineering contains over 100 full color pages of the latest state-of-the art products from Omega’s automation line: programmable logic controllers, smart relays, enclosures, process measurement and control devices, motion control sensors, human machine interface, pushbuttons, proximity sensors, relays and timers, wire connection and more. A user-friendly index is available for easy product search, economical choices, popular models and accessories.

Omega Engineeringwww.omega.com

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Automated Boiler Blowdown Control SystemThe automated Model 61 Boiler Blowdown Control System from Electro-Chemical Devices offers a complete system providing continu-ous control of the surface blowdown rate for commercial and industrial boil-ers, optimizing blowdown cycles and reducing scaling and corrosion, according to the manufacturer. With its precision accuracy, the automated Model 61 Boiler Blowdown Control System reduc-es boiler maintenance make-up water consumption and the energy needed to heat it. In comparison to perform-ing blowdown cycles manually, the system offers operational cost advan-tages by continuously adjusting the blowdown rate to optimize the boiler water’s electrolytic conductivity.

Electro-Chemical Deviceswww.ecdi.com

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Flowmeters for Chilled Water and Steam Flow MeasurementEngineers and facility opera-tors who need to measure steam or chilled water for either district energy, power plants and/or facil-ity HVAC control systems will find McCrometer’s FPI Mag (Full Profile Insertion) and V-Cone Flowmeters provide superior performance with installation flexibil-ity and low maintenance at economi-cal life-cycle costs, according to the manufacturer. The hot tappable FPI Mag Flowmeter is ideal for measuring chilled water in large campus evapo-rative HVAC systems. The advanced V-Cone Flowmeter delivers precision steam measurement in a space-sav-ing design.

McCrometerwww.mccrometer.com

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Industrial facilities often believe they have equipment lubrication covered with existing tools and systems — from spreadsheets to condi-tion analysis to sophisticated preventive maintenance (PM) and corrective maintenance (CM) programs. However, despite millions of dollars spent to improve machine condition and reliability, improper lubrication is still cited as the primary cause of premature equipment failure today.

“Lubrication is the neglected stepchild of equipment reliability and doesn’t get the attention it deserves,” says James Wanstreet, the reliability engineer and Lubrication Department supervisor at KapStone Paper and Packaging Corporation’s Charleston Kraft paper mill in Charleston, S.C.

As the limits of existing lubrication tracking methods become more apparent, separating lubrication from traditional PM and CM efforts to focus on lubrication reliability is increasingly being adopted as a solution.

Lubrication Tracking Methods Fall ShortPerforming lubrication seems elementary and has been approached

the same way for many decades. However, it is much more complex than it is given credit for.

“With almost 500,000 lube tasks a year in our plant on almost 8,000 pieces of equipment, it’s critical that the correct lubrication get done without fail,” says Wanstreet. “Lubrication is the life blood of plant equipment and foundational to keeping it working correctly.”

While lube tasks are considered routine and often assigned to the newest techs at the plant, it is critical to get the right lubricant in the right place at the right time using the right procedure or technique.

Yet it is far too easy to miss lube points, mix up lubricants or over/under lubricate when relying on traditional lubrication tracking methods.

Traditional Lubrication MethodsAt its most basic, plants rely on a technician armed with a grease gun

and human memory to track lube points. Although these technicians do a stellar job with the tools they are given, human memory is fallible and mistakes can be made and lube points missed.

“Even the smartest, most meticulous technician can forget things from day to day,” says Wanstreet.

Another solution used in many plants is the ubiquitous spreadsheet. Spreadsheets can be used to store or change information, but are inherently static and offer no real lubrication point tracking or history. For example, spreadsheets do not calculate and schedule future lubrica-tion tasks based on completing a current task. And if a lubrication task is missed, there’s no record of it.

Although early detection tools are used to identify and address a prob-lem before it worsens, this approach is really more reactive than proac-tive. After all, if lubrication is poorly managed, early detection tools are going to repeatedly indicate a problem. Proper lubrication, on the other hand, can prevent damage or excess wear before it starts.

Although CMMS systems work very well for managing PM and corrective work at the equipment level, they are not built for detailed tracking of individual lube tasks, particularly at high volume. Even so,

Getting Serious

About LubricationWhy Many Lubrication Tracking Methods Fall Short



31


CMMS systems are often utilized for this very purpose and this is where the difficulty begins.

To compensate for a lack of lubrication focus and detail, CMMS sys-tems rely on a series of lubrication PMs, arranged according to lubricant type, frequency and plant location. However, it can be time consuming to sort through multiple PMs to view lubrication requirements for a spe-cific piece of equipment. Furthermore, if a change is required to the type of lubricant, which is typically stored in a text field, or frequency, each applicable PM must be found and each detailed line item requiring a change corrected.

A New Focus on Lubrication Reliability

What’s needed is an approach dedi-cated to lubrication because hundreds of thousands of annual lubrication tasks are virtually impossible to adequately manage through human memory, a spreadsheet, early detection tools or buried in lists of PM work orders.

Fortunately, dedicated lubrication soft-ware is now transforming industrial lubri-cation management from an error-prone manual chore or inadequate CMMS effort into a predictable, automated process.

For instance, LUBE-IT by Generation Systems, an Issaquah, Wash.-based devel-oper of lubrication-specific tracking and management software, offers task specific scheduling and tracking management to ensure that the right lubricant gets to the right place at the right time in the right amount, using the right procedure or technique, all the time.

Each lube point and related tasks are inventoried including location, capacity, activity type, procedure, frequency, route and shutdown requirements. From that, the software manages all these lube tasks automatically and simplifies changes to any of the variables as needed. Once it has all the lube points, the software will reschedule a task based on when it was completed.

In this way, the software takes respon-sibility for hundreds of thousands of lubri-cation tasks annually, essentially ensuring that none are left behind as a result of the tracking/organizational system itself.

KapStone Paper and Packaging Corporation’s Charleston Kraft paper mill turned to Generation Systems’ dedicated lubrication management software.

With the software, reliability engineers and plant managers can quickly view the details and history of any lubrication point, including notifications of any equipment issues identified during the lubrication activity.

Details for each lube task are available via paper-based lists or rugged mobile computing devices so lubrication tasks that need to be completed are clear and known each week. Since the software dynamically releases that work for individ-ual tasks, the lube tasks will only appear

when needed based on its frequency. “Since we’ve been using LUBE-IT, we’re staying on top of lubrication

tasks without forgetting any,” concludes Wanstreet. “I estimate we’re getting about 25 percent more equipment uptime with fewer staff, with ROI in about one year.”

Generation Systems Inc.www.generationsystems.com

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32 Plant Maintenance & Safety

Instrument Power SupplyThe Instrument Power Supply with bat-tery power provides uninterrupted 24VDC for standard monitoring equip-ment. The three-stage battery charger, powered by 115/230 VAC at 50 to 60 hertz maintains the 12 VDC battery at

peak perfor-mance levels. The power system is designed to maintain a full charge that will provide 24VDC output dur-

ing a loss of AC power for up to three days, according to the manufacturer. Membrane panel status lights provide diagnostic information for various sys-tem configurations. Optional RS232 seri-al port and relay interface module relays provide a variety of output information possibilities.

Halogen Valve Systems Inc.www.halogenvalve.com

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Industrial SounderThe new PATROL Model PA 1 from Pfannenberg is a new generation, 100 db industrial sounder. By electroni-cally generating acoustic tones (no moving parts), reliability is one of the greatest benefits, according to the manufacturer. Mechanically, the housing is manufactured from a blend of polycarbonate and ABS for durability.

Pfannenberg Inc.www.pfannenbergusa.com

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While most reading this article may be unfamiliar with the Kopp Glass name, most are likely familiar with Kopp Glass products. From a humble beginning more than 80 years ago as a manufacturer of red glass for railroad signals, Kopp now claims to be the world’s leading producer of

precision molded industrial quality technical glass. The company is known worldwide among the industries it serves as a

producer of molded borosilicate glass, a tough material that can with-stand harsh industrial environments and is resistant to degradation from

sunlight and weathering. The company offers more than 300 standard glass compositions, plus custom formulations, in any desired shade of color.

The glass is used worldwide in such diverse applications as airport and air-craft lighting, chemical process equip-ment, medical device illumination, light filters of all types (including military night vision equipment), electrical transform-ers, architectural and theatrical lighting — and railroad and traffic signals. Kopp glass can even be found at the South Pole, where scientists have installed a computerized network of thousands of 14-inch-diameter (35.5 cm) glass globes about a mile below the surface of the ice. The globes contain sensors, with the goal of capturing sub-atomic particles, called neutrinos.

Kopp produces its glass in small batches, typically in the range of 100 to 1,000 pieces, says David Pungratz, the company’s mix and melt manager. The

The Importance of

Thorough MixingGlass Blended Rapidly with Abrasion-Resistant Rotary Mixer


The lange of a discharge valve at the hopper’s outlet is positioned atop the inlet of the mixer using an overhead hoist and trolley,

due to ceiling height restrictions.

35

powdered ingredients are mixed, melted in a pot furnace, then molded by skilled craftsmen. “All our products are made by hand,” he says.

The Importance of Thorough MixingThe mixer is a vital part of Kopp’s operation. “A batch may contain

anywhere from five to 15 ingredients that must be mixed thoroughly in order to guarantee product quality,” says Pungratz.

Kopp uses a rotary mixer made by Munson Machinery Co., Inc. of Utica, N.Y. It replaced a rotary pan mixer that had been in the plant for many years. The rotary mixer is a horizon-tal, rotating drum that is supported on either end by trunnion rings and driven by rollers, powered by a 5 hp (3.7 kW) motor. It has a stationary inlet at one end and a stationary outlet, with a discharge gate, at the other end. Mixing flights or baffles tumble the batch in a multi-direc-tional manner.

While many ingredients are used in Kopp’s products, sand accounts for 60 to 75 percent of a formulation, so sand is delivered to a silo in tanker trucks of 40,000 lb (18,144 kg) capacity. The rest of the ingredients, including borax, metal oxides and various other minerals, arrive in bags, drums or barrels.

The ingredients for a batch are loaded into a large rectangular hopper that is set on load cells. Sand from the silo is fed to the hopper by means of a screw conveyor and a chute. When the amount of sand reaches the preset weight, an

operator manually shuts off the conveyor. Other major ingredients are added manually, one by one. Finally, the minor ingredients, which are pre-weighed, are introduced into the batch.

When the batch is complete, the hopper is raised into position above the mixer’s inlet by an overhead hoist and trolley. The flange of a dis-charge valve at the bottom of the hopper rests on a rubber seal affixed to the mixer’s inlet, after which the valve is opened and material flows into the machine, aided by two vibrators located on the exterior of the hopper.

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Access doors facilitate interior inspection, cleaning

and maintenance.

The batch is rapidly discharged from the mixer into a

cart that transports it to the furnace.


Mixing is Rapid The mixer (model GB10 glass batcher) has a capacity of 10 cu ft (2.8

cu m), or 1,500 lb (680 kg) for glass. However, Kopp’s operation is lim-ited to 700 lb (317 kg) by the size of the hopper. Pungratz explains that larger hoppers cannot be used because of the limited clearance above the mixer.

The liner and other contact surfaces in the glass batcher are made of abrasion resistant steel, designed to withstand the abrasive mixture of ingredients, particularly sand, in Kopp’s formulations. Mixing times are

only about five minutes — less than half the time required by the pan mixer, says Pungratz. Nevertheless, the machine’s slow tumbling action, aided by the baffles, makes for “a homoge-neous mix. We make the best hand-pressed glass in the world, with minimal defects,” he asserts, “so our standards are very high.”

Once a batch has been mixed it is discharged into a wheeled cart or wagon and taken to a furnace. Kopp has two furnaces, one of which can accommo-date 16 melting pots and the other 12 pots. Most of the pots have a glass capacity of 2,500 lb (1,134 kg). The furnace oper-ates at 2,600 F (1,427 C), but the temperature of each pot can be individually controlled and ranges from 2,000–2,500 F (1,093–1,370 C), depending on the composi-tion of the glass.

A Matter of Individual SkillWhen a batch of glass is ready

for use the pot is opened and cooled to a working temperature, then the glass is cast in molds of stainless steel or cast iron. This operation is carried out by two skilled craftsmen, whose respec-tive job titles are glass gatherer and presser.

Each piece is made individually.

36 Powder & Bulk Solids

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dry bulk materials and solids-laden slurries—at rates from several pounds/kilograms to 70+ tons/h— with Quick-Clean CENTRI-SIFTER™ centrifugal screeners.

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Kopp replaced a rotary pan mixer with a

Munson rotary batch mixer — a horizontal,

rotating drum with a stationary inlet at one

end and a stationary outlet at the other. Mix-

ing lights, or bafles, tumble the batch in a

multi-directional manner.

“We just have to grease a couple of fittings about every two weeks, and in the six years we’ve owned the machine we have not seen any wear on the liner and have had to replace only one seal.”


37

The gatherer accumulates the appropriate amount of glass needed for the piece, using a punty — a steel rod that has a clay ball on one end. The punty is placed into the mouth of the pot until it touches the molten glass, then the punty is turned in a way that gathers glass on the clay ball. The glass is carried to and released into the mold and the presser shears off the flow, then pulls a lever to bring the plunger (the mold’s male part) into the mold.

Pungratz notes that the glass gatherer and the presser use their expe-rience to calculate the exact amount of glass needed for a piece. Large products, such as 24 inch-diameter (61 cm dia) Fresnel lenses, are made by layering three molten gobs of glass.

Meanwhile, the mixer provides a continual supply of mixed glass ingredients to the fur-naces. As soon as one batch has been dis-charged, the machine is cleaned and readied for the next batch. The machine processes 10 to 20 batches per day, typically of several dif-ferent colors, so it is important to avoid resi-due from one batch that might contaminate the next one.

However, contamination has not been a problem with the glass batcher, says Pungratz. Essentially all the material is rapidly discharged, leaving minimal residue, he says, and cleaning takes only about 10 minutes, using a dedicated vacuum. A door on the side of the machine provides full access to the interior.

A second vacuum system removes any airborne dust that results from the cleaning operation. However, in contrast with the pan mixer, the rotary mixer generates very little dust, says Pungratz, and “this was a big selling factor for us.” He adds that the rotary machine is “extremely quiet, while the pan mixer was very noisy.”

Another big advantage is that the mixer is essentially maintenance-free, he says. “We just

have to grease a couple of fittings about every two weeks, and in the six years we’ve owned the machine we have not seen any wear on the liner and have had to replace only one seal.”

Munson Machinery Co., Inc.www.munsonmachinery.com

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38 Powder & Bulk Solids

Dust-Tight Drum Discharging SystemMTS hydraulic Lift & Seal System™ seals drum to a dust-tight pour cone with outlet valve for a clean, contam-inant-free product transfer. Patented Control Link™ Rotation System pro-

vides 180-degree drum rotation for maximum prod-uct discharge. Interior of pour cone features fluidizing pads and a material agitator. Units are available with discharge heights up to 40 feet,

rotation to 180 degrees, for any size drum or container. Systems are cus-tom designed to meet your applica-tion requirements.

Material Transfer & Storagewww.materialtransfer.com

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Bulk Bag ConditionerThe new BLOCK-BUSTER™ Bulk Bag Conditioner from Flexicon Corporation is equipped with two hydraulic rams and specially contoured end plates. The conditioner presses opposing sides of bulk bags, loosening material that has solidified during storage and shipment, enabling bulk bag unloaders to discharge through bag spouts. A cantilevered I-beam with motorized hoist and trolley allows loading and unloading of bulk bags without the use of a forklift.

Flexicon Corporationwww.flexicon.com

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Sanitary Pin MillA new 34-inch sanitary stainless steel Pin Mill model CIM-34-SS from Munson Machinery provides coarse to fine grinding of friable powders, flakes and granules into controlled particle sizes. High-speed rotation of the inner disc creates centrifugal force that acceler-

ates bulk mate-rial entering the central inlet of the oppos-ing stationary disc. As material travels from the center to the

periphery of the discs at high speed, it passes through a path of five inter-meshing rows of rotating and stationary pins, with the desired tight particle size distribution obtained by controlling the rotor speed.

Munson Machinerywww.munsonmachinery.com

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Modular SifterThe Modular Tru-Balance sifter from Great Western Manufacturing is a simple and economical machine with reliable per-formance and excellent sanitation features, which are ideal when requirements do not dictate stainless steel construction or complex separations. The Modular Tru-Balance Sifter utilizes four to nine sieves and can obtain up to three separations. Numerous construction options means the Tru-Balance Modular sifter can be adapted to a wide range of products.

Great Western Manufacturingwww.gwmfg.com

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Two-Deck Sanitary ClassifierA new Vibroscreen® Two-Deck Sanitary Classifier from Kason Corp. separates up to six tons per hour of bulk solid material into three frac-tions, accord-ing to the manufacturer. Measuring 30 inches in diameter, it classifies mate-rials ranging from dry bulk solids to solids-laden slurries. It is constructed of stainless steel with ground and polished welds, and equipped with sanitary epoxy-mounted screens. Quick-disconnect clamps between each screen frame provide rapid interior access for inspection, screen changes and wash down.

Kason Corporationwww.kason.com

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Sieve Tower AnalyzerHK Laboratory/Pilot Sieve Towers from Cleveland Vibrator Company have a unique, heavy-duty, vibra-tory design that enables quick sieve analysis of product samples with maximum throughput. With a choice of an optional electro-magnetic jogger table, or standard dual outboard rotary electric drives, users are equipped with variable speed set-tings that permit complete control. Units are available in 8-, 12- or 17-inch diameter sieve sizes down to 635 mesh. Additional features include electric or air operation for tabletop or caster use and quick clean-up.

Cleveland Vibrator Companywww.clevelandvibrator.com

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40 Tanks & Vessels

Liquid and Dry Bulk Storage SystemsCST Storage and CST Covers offer flexible and integrated liquid and dry bulk storage system design options for applications worldwide. CST Storage (formerly Columbian

TecTank and Engineered Storage Products) is a provider of modular, fac-tory coated steel storage tanks and cov-ers, offering glass-fused-to-

steel (Aquastore) and epoxy coated (BulkTec and HydroTec) tanks appropriate for nearly all liquid and dry bulk storage applications. CST Covers deliver engineered cover solutions in aluminum domes, flat panel covers and custom structures appropriate for CST Storage tanks as well as new and pre-existing con-crete and steel tanks.

CST Industrieswww.cstindustries.com

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Corrosion- and Chemical-Resistant Polyethylene TanksAssmann Corporation has a full line of corrosion- and chemical-resistant tanks and containers. Constructed from virgin high-density crosslink or FDA-compliant linear polyethylene, the tanks and containers are used to store and transport corrosive and hazardous materials. They provide low-temperature impact resistance, are UV stabilized and come in wide range of capacities and colors. Custom rotational molding, accessory fittings and custom colors are available.

Assmann Corporation of Americawww.assmann-usa.com

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Compare which Tanks & Vessels are best for your application at ProcessFlowDirect.com.

ProcessFlowDirect


Largest Vibratory Classifer Separates Up to 70 Tons/hVibroscreen® High Capacity, Two-Deck Classifier separates up to 70 tons/h of bulk chemi-cals, minerals, plastics, foods, pharmaceuticals and other materials into three fractions. Operates on a batch or con-tinuous basis.

Kason [email protected]•www.kason.com973-467-8140

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Prevent Chemical Spills with Double Wall TanksCylindrical double wall tanks from Assmann Corporation provide the best protection against hazardous chemical spills. Assmann’s molding pro-cess provides a heavier-top sidewall and dome to prevent dome collapse.

Assmann Corporation of Americawww.assmann-usa.com/Double_Wall_Tanks.htm

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Stainless Steel Tube Fittings20-page catalog from CPV Manufacturing describes Mark VIII O-SEAL stainless steel tube fittings that will not shake loose. Unique leakproof sealing system allows easy slip-in, slip-out connections matched to your system.

CPV Manufacturing, Inc.851 Preston St.Philadelphia, PA 19104215-386-6508•Fax215-387-9043www.cpvmfg.com

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Hannay Reels SS3000 Series for Sensitive and Harsh EnvironmentsHannay Reels’ SS3000 Series of stainless steel reels provides superior protection against cor-rosion. Paint-free surface elimi-nates the potential for rusting associated with chipping.

Hannay [email protected]•www.hannay.com

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Fast Homogeneous MixingTheBellaFluidizedZoneMixerby Dynamic Air achieves fast, high-capacity, low shear, preci-sionmixingofeitherdrybulksolids or liquids with solids. Regardless of particle size, shape or density, materials are mixedwithafast,eficientandgentle action.

Dynamic Air Inc.St. Paul, MN 651-484-2900 [email protected]•www.dynamicair.com

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Efficient Plastic Diaphragm Valve SolutionThe new R677 and R690 Diaphragm valves from GEMU have been designed to be a highly efficient plastic dia-phragm valve solution. The optimized internal geom-etry provides higher Cv’s and improved flow characteristics.

Gemü Valveswww.gemu.com

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Packaging Protection for any ProductPlastic netting from Caplugs is used as packaging protection for just about any product. The netting is available in flat sheets for layering or in sleeves to slip over an object. The netting cushions your product during shipment, which keeps it free of damage.

Caplugs1-888-CAPLUGSwww.caplugs.com

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NEW Brochure!VAC-U-MAX, a custom builder of pneumatic conveying sys-tems for bulk powders, intro-duces a NEW brochure detail-ing the capabilities and 50+ years in the bulk dry powder industry.

VAC-U-MAX800-VAC-U-MAX•www.vac-u-max.comEmail:[email protected]

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Pressure Measurement for Process IndustriesKeller manufactures pressure measurement instruments utiliz-ing state-of-the-art electronics and proven piezoresistive tech-nology to provide outstanding accuracy, longevity and price. For more information, please call us or visit our website.

Keller America, Inc. 877-253-5537www.kelleramerica.comEmail: [email protected]

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High Accuracy Digital Pressure GaugesOmega’s new DPG409 series of high accuracy digital pressure gauges feature a large backlit display makes it possible for user to read digits from over 10.7m (35 ft). The rugged Stainless Steel enclosure is designed spe-cifically for wash-down, sanitary and marine applications.

OMEGA ENGINEERING, INCOne Omega Drive, Stamford, CT 06907

203-359-1660 • Fax: 203-359-7700www.omega.com

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Model 3012 DSP Screw PressThe Screw Press is the ideal choice for the small WWTP plant with a low washwater require-ment. An independent pre-thickening rotary drum thickener enhances capacity and cake solids. In-house fabricated slotted screen allowsformaximumdrainageandavoids plugging or blinding.

BDP Industries www.BDPIndustries.com

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Model 60B Flow ComputerThe 60B Flow Computer constantly processes pressure, temperature and flow data from a Laminar Flow Element (LFE) with a resulting accurate (±.75 percent of point-NIST traceable) display of Standard (Mass) and Volumetric flow. Totalizers and optional outputs are available.

CME, Div. of Aerospace Control Products1314 West 76th Street, Davenport, IA 52806 www.cmelow.com•E-mail:[email protected] 800-845-0927

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41Info Center


42 Info Center

Krytox® Fluorinated LubricantsKrytox® Greases and Oils are: chemically-inert; nonflammable; thermally stable, -103 to 800 F; oxygen-compatible; no migra-tion; low outgassing. Krytox® offers extreme pressure, anti-corrosion and anti-wear proper-ties. Mil-spec, aerospace and food grades!

Miller-Stephenson Chemical Co., Inc.California - Illinois - Connecticut - Canadawww.miller-stephenson.com Email: [email protected]

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High Performance MixersPHLAUER High Performance Mixers are solving customers’ mix-ing problems by providing repeat-able, predictable, reliable perfor-mance. Accurate mixing to 0.5 percent standard deviation and Cv of 5 percent in small samples. Single and double rotor machines with shear available on demand.

A&J Mixing International Inc.8-2345 Wyecroft Road, Oakville, ON www.ajmixing.com•Email:[email protected] 800-668-3470•FAX:905-827-7288

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Loss-in-Weight FeedersThe MECHATRON® Loss-in-Weight Feeders provide processing industries precise material feeding accuracies of ±1/4 to 1 percent of feed rate setpoint at 2 sigma. Complete disassembly from the non-pro-cess side of the feeder. Feed rates from .002 to 1,100 ft³ per hour are achievable.

Schenck AccuRate746E.MilwaukeeStreet,Whitewater,WI53190800-558-0184www.accuratefeeders.com/mechatronfeeders.html Email: [email protected]

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Portable FlowmeterMount the ultrasonic sensor on the outside of a pipe and this new PDFM 5.0 Portable Doppler Flowmeter shows flow rate instantly. Use it for flow troubleshooting, spot checks or balancing flow.

Greyline Instruments Inc. 105 Water Street, Massena, NY 13662 888-473-9546 www.greyline.com Email: [email protected]

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Dry Run ProtectionNew PMP-25 Pump Load Control guards against dry run-ning, cavitation and overload. It monitors true pump power for maximum sensitivity while displaying power, trip points and delays.The4X-enclosureissmallenough to fit on size 1 starters and can be door-, panel- or wall-mounted. Free 30-day trial!

Load Controls, Inc.www.loadcontrols.com888-600-3247

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Jefferson Stocks Stainless Steel ValvesSame day shipping on all valves we have in stock includ-ing stainless steel and brass solenoid valves. Jefferson stocks ALL seat materials such as EPMD, FKM, PTFE AND BUNA N. Cost-effective cross-over done on all valves.

Jefferson Valves 20225NE15thCt.,Miami,Fl33179www.jeffersonvalves.com305-249-8120

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Thermal Gas Flow Measurement Eldridge Products, Inc.’s new ValuMass™ Series 400 is a lower cost option for thermal gas mass flow measurement in a compact design. The Series 400 configurations accommo-date most installation require-ments.

Eldridge Products, Inc.www.ValuMass.com 831-648-7777

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Spherical Disc ValveThe P21 High Performance Spherical Disc Valve is designed to meet your demanding requirements for containment of solids, powders and slurries. Engineered for positive sealing in vacuum and pressure applica-tions, the P21’s original spheri-cal disc design eliminates the source of valve wear.

Gemco Valve301 Smalley Ave., Middlesex, NJ 08846 www.GemcoValve.com/seal 800-654-3626

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Linear and Rotary Control Valve ActuatorsRotork Process Control’s Product Catalog features the company’s new CVA line of linear and rotary control valve actuators. The line features auto calibration, continuous modulating duty and extremely precise accuracy.

Rotork Process Controls, Inc.675 Mile Crossing Blvd., Rochester, NY 14624 www.rotork.com•Email:[email protected]

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OFS Type 2 Seal ModelMECO’s OFS Type 2 seal model is ideal for blenders, mixers, cookers, conveyors and similar rotating equipment used in the food, pharmaceutical, chemical, plastics, metals and other bulk process industries. Sized for OEM and custom process equipment.

MECO Shaft Sealswww.woodex-meco.com

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Solenoid ValvesCatalog details 2-way bronze and stainless steel solenoid valves 1/4” to 3” to control the flow of water, ammonias, fuel oil, gas, steam, brine, solvents, cryogenics and oxygen. Valves are available NC/NO, packless construction and continuous-duty coils for all voltages.

Magnatrol Valve Corporation67 Fifth Ave., PO Box 17, Hawthorne, NJ 07507 www.magnatrol.com•E-mail:[email protected] 973-427-4341•FAX:973-427-7611

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Tigerflex Material Handling HosesTigerflex™ offers unique mate-rial handling hoses designed to dissipate static electricity via embedded copper grounding wires or use of anti-static PVC compounds. Clear construction materials allow for visual confir-mation of material flow.

Kuriyama of America, Inc.www.kuriyama.com

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Coming in the next issue of Powder Handling Solutions! Controlling Explosion Hazards of Dust Collection SystemsVahid Ebadat, CEO of Chilworth Global North America, explains common options for ensuring the safety of dust collection systems.

Bulk Bag Handling System Slashes Carbon Black Inventory Elastomer manufacturer Kirkhill-TA slashed inventories of carbon black by 90 percent and improved plant cleanliness by replacing a large silo storage system with a bulk bag discharging system.

www.processingmagazine.com

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44 IndexA d v e r t i s e r I n d e x

CompressorsAlmasi Column ………………………………………………… 12

Food EquipmentEaton …………………………………………………………… 26Ingredient Masters …………………………………………… 20NuTEC Manufacturing ………………………………………… 28Sensorex ………………………………………………………… 28Solimar Pneumatics …………………………………………… 28

InstrumentsBanner Engineering …………………………………………… 36Dwyer Instruments …………………………………………… 37KEYENCE Corp. of America ………………………………… 37Sierra Monitor Corporation …………………………………… 36VEGA Americas Inc. ………………………………… Front CoverWeidmuller …………………………………………………… 37Yokogawa Corporation of America ………………………… 36

Mixing & Size ReductionCharles Ross & Son Company ………………………………… 8Chemineer ……………………………………………………… 10IKA Works, Inc. ……………………………………… Front CoverNational Bulk Equipment Inc. …………………………………… 8Neptune Mixer Company …………………………………… 10Stedman ………………………………………………………… 8Westfall Manufacturing Company …………………………… 10

Plant AutomationElectro-Chemical Devices …………………………………… 29McCrometer …………………………………………………… 29Omega Engineering …………………………………………… 29

Plant Maintenance & SafetyBanner Engineering ………………………………… Front CoverGeneration Systems …………………………………………… 30Halogen Valve Systems Inc …………………………………… 32Pfannenberg Inc. ……………………………………………… 32

Powder & Bulk SolidsACS Valves …………………………………………… Front CoverCleveland Vibrator Company ……………………………… 39Flexicon Corporation ………………………………………… 38Great Western Manufacturing ……………………………… 39Kason Corporation …………………………………………… 39Material Transfer & Storage ………………………………… 38Munson Machinery …………………………………………… 38

Pumps & SealsEdwards ……………………………………………………… 16ITT Goulds …………………………………………… Front CoverKNF Neuberger Inc. …………………………………………… 14Mackay Column ……………………………………………… 18Moyno, Inc. …………………………………………………… 14Trelleborg Sealing Solutions ………………………………… 16Watson-Marlow Pumps Group ……………………………… 16Wilden Pump & Engineering Company …………………… 14

Tanks & VesselsAssmann Corporation of America …………………………… 40CST Industries ………………………………………………… 40

Adalet ...................................................... 32

A & J Mixing ........................................... 37

Assmann Corporation of America .......... 10

A-T Controls, Inc. ....................................... 7

Atlantic Coast Crushers ............................ 6

Baldor ......................................................... 1

Benko ....................................................... 37

BinMaster Level Controls ......................... 40

Boerger .................................................... 11

Bredel Hose Pumps .................................. 13

Bunting Magnetics .................................. 24

Caplugs .................................................... 29

Cardinal Scale Manufacturing .................. 22

Carter Day ................................................ 30

Cashco ....................................................... 4

Charles Ross & Son Company ................... 5

Chemineer ................................................ 24

CST Industries .......................................... 16

Federal Equipment................................... 34

Fenwal Inc. ............................................... 31

Franklin Miller, Inc. ................................... 10

Gamajet .................................................... 40

Grainger ................................................... 33

GreCon ..................................................... 32

Halogen Valve Systems ............................ 34

Hannay Reels ............................................ 28

Hapman .................................................... 19

IKA Works, Inc. ........................................... 9

Inpro/Seal ................................................. 17

Jefferson Solenoid Valves .......................... 8

Kason Corporation ................................... 36

K-Tron ....................................................... 25

Load Controls ............................................. 6

Lutz Pumps Inc. ........................................ 32

Magnetrol ................................................. 15

MasoSine Process Pumps ........................ 13

Material Transfer & Storage..................... 21

Neptune Chemical Pump Co. .................. 12

NETZSCH ................................................. 37

NPE ......................................................... 43

Omega Engineering ....... Inside Front Cover

Orion Instruments .................................... 23

Plast-O-Matic Valves ..................Back Cover

Practical Pumping .................................... 37

PTXi .......................................................... 39

Pump Symposium .................................... 38

Schenck AccuRate .................................... 26

seepex, Inc. .............................................. 18

Specialty Equipment .................................. 3

SPX Flow Technology ..... Inside Back Cover

Stedman Machine Co. .............................. 18

Super Radiator Coils ................................ 30

Swagelok .................................................. 14

Tel-Tru Manufacturing.............................. 36

Triple S Dynamics ..................................... 27

Union Process ........................................... 36

Vac-U-Max ................................................ 35

Woodex Bearing Company, Inc. .............. 12

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