FDAApproved Coke Vibration Screen Assembly Plant: Engineered for Purity, Efficacité, and Zero Contamination

1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing the final screening stage for foodgrade or pharmaceuticalgrade coke presents unique and costly challenges. A single contamination event can lead to an entire batch rejection, resulting in substantial financial loss and reputational damage. Are you facing these critical issues?

Risque de contamination du produit: Metaltometal contact, lubricant leakage from bearings, or particulate shedding from screen decks can introduce foreign materials into your product stream, violating FDA compliance and endangering consumer safety.
Suppression des amendes inefficaces & Product Degradation: Inconsistent vibration or poor screen deck design leads to blinding, débit réduit, and an inability to precisely separate fines. This results in offspec product and wasted yield.
Temps d'arrêt excessif pour maintenance: Standard industrial screens are not designed for the rigorous hygiene standards required. Nettoyage, inspection, and part replacement are timeconsuming, directly impacting your plant’s operational availability.
Corrosion & Sanitation Challenges: Residual coke particles and moisture in a standard assembly can promote corrosion within the frame and components, creating harborage points for bacteria and making FDAmandated cleaninplace (CIP) procedures ineffective.

La question centrale est: how do you achieve highcapacity, reliable particle sizing while guaranteeing a contaminantfree process that meets stringent regulatory audits?

2. APERÇU DU PRODUIT

This FDAApproved Coke Vibration Screen Assembly Plant is a complete, turnkey screening system engineered specifically for the final classification of calcined petroleum coke (CPC) intended for food, pharmaceutical, or other highpurity applications. It is designed as a fully enclosed unit to prevent external contamination and facilitate sanitation.

Flux de travail opérationnel:
1. Alimentation contrôlée: Prescreened coke is introduced via an FDAcompliant feed chute onto the first screen deck.
2. Séparation précise: Multiple screen decks with defined mesh sizes utilize controlled linear or elliptical vibration to stratify material efficiently, removing fines and oversize particles.
3. Clean Product Streams: Accepted product (intermédiaires) is discharged through dedicated, sealed outlets. Fines and oversize are separately conveyed to designated collection points.
4. Contained Environment: The entire screening process occurs within a sealed housing equipped with FDAgrade gaskets and inspection windows.
5. Sanitation Readiness: The system is designed for rapid washdown with sloped surfaces, quickrelease clamps on access panels, and drainage ports.

Champ d'application: Final sizing of food/pharmaceuticalgrade calcined petroleum coke (CPC), precision separation of specialty carbons.
Limites: Not intended for primary crushing of raw green coke or for extremely abrasive nonfood mineral processing outside its specified wear material grades.

3. CARACTÉRISTIQUES PRINCIPALES

Hygienic ClampTogether Assembly | Base technique: FDAcompliant 304/316L stainless steel construction with polished finishes | Avantage opérationnel: Eliminates bolt threads and lap joints that trap particles; enables rapid disassembly for inspection and cleaning | Impact sur le retour sur investissement: Reduces sanitation labor time by up to 60% versus bolted designs, minimizing production line changeover windows.

Sealed Vibration Mechanism | Base technique: Dusttight vibrator motor housings with FDAaccepted lip seals; optional internal air purge system | Avantage opérationnel: Prevents lubricant ingress into product zone and protects bearings from corrosive dust | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements de 23x, eliminating a primary source of product contamination and unplanned downtime.

QuickChange Screen Deck System | Base technique: Tensioned polyurethane or stainless steel mesh decks with sanitary attachment rails | Avantage opérationnel: Allows a single operator to replace screen panels in under 10 minutes without tools | Impact sur le retour sur investissement: Increases plant flexibility for different product grades and restores full capacity faster after maintenance.

Sanitary Frame Design | Base technique: Continuous welds polished to a 4 finition; coved corners; integrated CIP spray ball ports | Avantage opérationnel: Prevents material buildup and bacterial growth; supports validated cleaning protocols | Impact sur le retour sur investissement: Ensures continuous compliance with FDA audits, avoiding costly production halts for deep cleaning.

Optimized Vibration Dynamics | Base technique: Computermodeled vibratory motion tuned for coke particle flow characteristics | Avantage opérationnel: Minimizes particle degradation (usure) while maximizing screening efficiency and throughput per square foot of deck area | Impact sur le retour sur investissement: Improves yield of onspec product by 38% compared to poorly tuned industrial screens.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Industry Standard Screen Assembly | Our FDAApproved Coke Vibration Screen Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Sanitation Compliance Time | Manual scrubbing of complex assemblies (812 heures) | Validated CleaninPlace (CIP) procedure (100% Amélioration |
| Efficacité du dépistage (Précision) | ~8590% efficiency on fine meshes (<40 engrener) | Cohérent 9397% efficiency on same meshes | ~58% More Product Yield |
| Material Changeover Time (Deck Swap) | 4590 minutes with tools & multiple personnel | 30 RA standard mill finish 50% Smoother Surface |

5. SPÉCIFICATIONS TECHNIQUES

Capacité & Notation: Modèles de 20 TPH à 150 TPH throughput capacity for coke bulk density (~0,50,8 t/m³). Conçu pour 24/7 fonctionnement continu.
Exigences d'alimentation: Vibrator motors from 2 x 2 HP à 2 x 10 HP depending on model; standard supply at 460V/60Hz/3Ph; autres tensions disponibles.
Spécifications matérielles: Primary product contact surfaces: ASTM A270 compliant 4 polish finish stainless steel (304 or optional AISI316L). Structural frame members are carbon steel with corrosionresistant coating suitable for washdown environments.
Dimensions physiques: Variable selon le modèle; typical footprint range from \(3m L x \(1\).8m W\) jusqu'à \(6m L x \(2\).5m W\). Height typically under \(2\).5m including feed hopper.
Plage de fonctionnement environnementale: Ambient temperature range of \(0°C\) à \(40°C\) (\(32°F\) \(104°F\)). Tolérance d'humidité jusqu'à \(95\%\) sans condensation.

6. SCÉNARIOS D'APPLICATION

[FoodGrade CPC Producer] Défi: A major producer faced recurring audit findings due to potential crosscontamination in their final screening line using modified industrial equipment. Manual cleaning was inconsistent and documentation was inadequate.

[Specialty Carbon Manufacturer] Défi: Producing highvalue modified carbon required separating ultrafine particles (\(5\%\) fines generation).

[MultiGrade Coke Facility] Défi: The plant produced both industrialgrade et foodgrade coke on shared lines using the same equipment.

[FoodGrade CPC Producer] Solution: Implementation of two parallel FDAapproved vibration screen assemblies with CIP documentation packages.

[Specialty Carbon Manufacturer] Solution: Installation of a customconfigured assembly featuring polyurethane decks on all contact points

[MultiGrade Coke Facility] Solution: Installation of a dedicated hygienic assembly on the foodgrade line

[FoodGrade CPC Producer] Résultats: Achieved consistent audit readiness

[Specialty Carbon Manufacturer] Résultats: Achieved target purity specifications

[MultiGrade Coke Facility] Résultats: Enabled simultaneous production

7 CONSIDÉRATIONS COMMERCIALES

Our solutions are offered in three primary tiers:

1\. Niveau du système de base
Includes core hygienic assembly
starting at approximately $85
000 USD depending on size
et les besoins en capacité

Fonctionnalités facultatives:
• Advanced CIP automation package
• Explosionproof motor ratings
• Integrated metal detection systems
• Custom discharge spouting configurations
• Remote monitoring sensors

Forfaits de services:
• Mise en service & formation des opérateurs
• Annual inspection & certification program
• Priority parts fulfillment guarantee

Options de financement:
We work with thirdparty lenders
to offer equipment leasing structures
or extended payment terms over \[24\]
\[36\]
ou \[60\] mois

8 FAQ

Q1 Is this assembly compatible with our existing upstream crushers?
A1 Yes provided your feed material meets the specified size distribution Our engineering team can review your current process flow

Q2 Quel est l'impact attendu sur la consommation énergétique globale de notre usine?
A2 Field data shows these assemblies typically operate within industrystandard power bands The efficiency gains in yield often result in net energy savings per ton produced due to reduced recirculation loads

Q3 Are spare parts readily available given the specialized materials?
A3 We maintain an inventory of all critical wear items including sanitary gaskets specialized bearings etc ensuring nextbusinessday shipping availability under our service contracts

Q4 Can we conduct factory acceptance testing before shipment?
A4 Yes we strongly recommend FAT where we demonstrate performance metrics such as sanitation access noise levels etc prior to delivery This ensures all specifications are met before installation at your site