Our staff has considerable experience in designing mixing systems for cement, minerals, aquatic feed, pet food, spices—almost any application. We do a lot of work in existing buildings because of our high production from small machines, and can model the pieces so they fit the building and also fit together.
Systems may include design, mixers, weigh hoppers, receivers, discharge hoppers, structural concept, control panels, control systems, valves, scales, connectors, bag dumps, screw conveyors, bucket elevators, pail fillers, pail closers, conveyors, bulk bag unloaders, bulk bag fillers, screeners, metal detection, samplers, vacuum pumps, liquid pumps and spraying systems, dryer packages.
The benefits of buying a system are all economic:
- The components will be coordinated to get the best economic advantage and get the production rate required.
- Mixing times and shearing are fixed times so we know exactly what the other components must be capable of doing.
- When you install, all the components will fit. We pre-assemble in the shop and make sure all bolt holes align. Often we see square flanges dimensioned with reference to all four sides. This is a forming impossibility so there is little chance that two manufacturers working with such a drawing will have bolt holes align. This is a big cost in re-fitting in the field and lost production because of the delay.
- The system components need to have access for safe cleaning and for maintenance. Discharge hoppers, for example, need to provide access for cleaning and servicing a drop bottom discharge. The access doors can be on an angle and they are heavy. They need to be hinged in such a way that the weight is supported, so the person that opens the door can control and close it.
- From a controls point of view, the mechanical design must accommodate the controls. If a signal has to be n milliseconds long to be scanned, then it is a mechanical problem. All the switches are given to the programmer with a description of what the signal will be and how to program it for the mechanical design to function. The sophistication of the controls has to be at the level that you can find personnel to operate. We have one customer who is very aware of this and buys extra mechanical equipment to keep the controls simple.
- The same is true of mechanical components. For example, we have many installations where the maintenance people cannot repair mechanical seals. We have our own design which is easy to maintain.
- Adequate safety factors in the design. The mixer should always be ready and waiting for the next operation unless it is a continuous system. Our design is typically 20% more than the production required. We have always made the production rate, and in many cases the system will operate at our design rate. For example, we designed an adhesives system to do 80 metric tonnes in 8 hrs, and full 480 minutes of operation. We designed for 100 tonnes. The system started at 100 tonnes and is now being pushed to 117 tonnes, and 5 years without significant lost time for maintenance. The customer got a payback in 4 months. With quality and production, they did aggressive marketing and product development, and dominate their market.
We have since shipped to them a 100 tonne color line, and another adhesive line for 200 tonnes. With the color line, they are saving 10 to 20% in pigments.
- We do not believe in “turnkey” systems. They lose the “n”. No one can walk off the street and know your business better than you do, and no one knows our equipment better than we do. We want a cooperative effort throughout the project so we do not lose your marketing advantage; and when we are finished, you know how to operate the system.
- We will work with you in any manner. If you want to buy equipment from other vendors and have us co-ordinate, we do that all the time. We may want to specify what you buy. We also prime jobs when the other pieces are smaller. Both give you one source responsibility and one phone call when you need help. We can also be your source for parts.
- You will find our systems very competitive. With High Performance Mixers, the cost per ton is always less. With a conventional mixer typically you need more space, more structure; the engineering, controls, and other components will be the same cost, with perhaps 2/3 the production rate. Be sure to consider your profit per ton on the extra production, and also what it will cost you over ten years if you don’t buy. We have a working spread sheet that you may use and insert your own numbers.
In addition, the conventional mixer may not have a fixed mix time for any or all products which will involve more QC checks and re-mixing, which will have to be considered in the design.
This system was designed to produce 80 metric tons
per shift of cement adhesives. The heart of the
system is a Carbon/AR400 1700 liter mixer.
The process is semi-automated using scales
and PLC. Cement is weighed in a weigh hopper.
Sand is in a holding hopper and weighed directly
into the mixer. Hand adds are manual.
The PLC weighs the majors, prompts for
hand adds, then mixes and discharges.
Because of the success with the 80-tonne system
having predictable, repeatable and reliable quality
and production, our customer was able to greatly
improve their sales, profits, and cash flow.
They needed more production so the system
immediately above was purchased to produce
200 tonnes per shift of thinset mortars. The
batch size is 5 metric tones, and the total
cycle about 9.5 minutes which keeps the mixing
ahead of the baggers. The operation is similar
to the 80-tonne system except the sand is
put in the mixer using loss-in-weight
in the holding hopper.
PLUG AND PLAY” MIXER, DUST COLLECTION, PAIL FILLING
The PHLAUERTM Model AJSP304SPIS is shown with
the filtered bag dump which is also piped to collect dust
from the heavy duty pail filler under the mixer. The system comes
complete with the control panel, programmed scale and
gravity conveyor. The batch is loaded manually in the
mixer and mixed. The mixer is switched to slow
speed for filling pails. The operator puts in the weight to be
put into the pail and sits the pail on the scale. If the pail is
within the tare band for the selected weight, then the system
tares and fills the pail, with a full and dribble feed to get the accuracy.