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

1. PEMBUKAAN PAINPOINT DRIVEN

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?

Risiko Pencemaran Produk: 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.
Inefficient Fines Removal & Product Degradation: Inconsistent vibration or poor screen deck design leads to blinding, daya pengeluaran berkurangan, and an inability to precisely separate fines. This results in offspec product and wasted yield.
Masa Henti Penyelenggaraan Berlebihan: Standard industrial screens are not designed for the rigorous hygiene standards required. Pembersihan, pemeriksaan, and part replacement are timeconsuming, directly impacting your plant’s operational availability.
kakisan & 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.

Persoalan utama ialah: how do you achieve highcapacity, reliable particle sizing while guaranteeing a contaminantfree process that meets stringent regulatory audits?

2. GAMBARAN KESELURUHAN PRODUK

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.

Aliran Kerja Operasi:
1. Suapan Terkawal: Prescreened coke is introduced via an FDAcompliant feed chute onto the first screen deck.
2. Pemisahan Tepat: 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 (orang tengah) 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.

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

3. CIRI TERAS

Hygienic ClampTogether Assembly | Asas Teknikal: FDAcompliant 304/316L stainless steel construction with polished finishes | Faedah Operasi: Eliminates bolt threads and lap joints that trap particles; enables rapid disassembly for inspection and cleaning | Kesan ROI: Reduces sanitation labor time by up to 60% versus bolted designs, minimizing production line changeover windows.

Sealed Vibration Mechanism | Asas Teknikal: Dusttight vibrator motor housings with FDAaccepted lip seals; optional internal air purge system | Faedah Operasi: Prevents lubricant ingress into product zone and protects bearings from corrosive dust | Kesan ROI: Memanjangkan hayat perkhidmatan galas sebanyak 23x, eliminating a primary source of product contamination and unplanned downtime.

QuickChange Screen Deck System | Asas Teknikal: Tensioned polyurethane or stainless steel mesh decks with sanitary attachment rails | Faedah Operasi: Allows a single operator to replace screen panels in under 10 minutes without tools | Kesan ROI: Increases plant flexibility for different product grades and restores full capacity faster after maintenance.

Sanitary Frame Design | Asas Teknikal: Continuous welds polished to a 4 finish; coved corners; integrated CIP spray ball ports | Faedah Operasi: Prevents material buildup and bacterial growth; supports validated cleaning protocols | Kesan ROI: Ensures continuous compliance with FDA audits, avoiding costly production halts for deep cleaning.

Optimized Vibration Dynamics | Asas Teknikal: Computermodeled vibratory motion tuned for coke particle flow characteristics | Faedah Operasi: Minimizes particle degradation (pergeseran) while maximizing screening efficiency and throughput per square foot of deck area | Kesan ROI: Improves yield of onspec product by 38% compared to poorly tuned industrial screens.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Industry Standard Screen Assembly | Our FDAApproved Coke Vibration Screen Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Sanitation Compliance Time | Manual scrubbing of complex assemblies (812 jam) | Validated CleaninPlace (CIP) procedure (100% Penambahbaikan |
| Kecekapan Saringan (Ketepatan) | ~8590% efficiency on fine meshes (<40 mesh) | Konsisten 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. SPESIFIKASI TEKNIKAL

Kapasiti & Penilaian: Model dari 20 TPH kepada 150 TPH throughput capacity for coke bulk density (~0.50.8 t/m³). Direka untuk 24/7 operasi berterusan.
Keperluan kuasa: Vibrator motors from 2 x 2 HP ke 2 x 10 HP depending on model; standard supply at 460V/60Hz/3Ph; voltan lain yang tersedia.
Spesifikasi Bahan: 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.
Dimensi Fizikal: Boleh ubah mengikut model; typical footprint range from \(3m L x \(1\).8m W\) hingga \(6m L x \(2\).5m W\). Height typically under \(2\).5m including feed hopper.
Julat Operasi Persekitaran: Ambient temperature range of \(0°C\) ke \(40°C\) (\(32°F\) \(104°F\)). Toleransi kelembapan sehingga \(95\%\) tidak terkondensasi.

6. SENARIO APLIKASI

[FoodGrade CPC Producer] Cabaran: 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] Cabaran: Producing highvalue modified carbon required separating ultrafine particles (\(5\%\) Denda Generasi).

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

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

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

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

[FoodGrade CPC Producer] Keputusan: Achieved consistent audit readiness

[Specialty Carbon Manufacturer] Keputusan: Achieved target purity specifications

[MultiGrade Coke Facility] Keputusan: Enabled simultaneous production

7 PERTIMBANGAN KOMERSIL

Penyelesaian kami ditawarkan dalam tiga peringkat utama:

1\. Peringkat Sistem Asas
Includes core hygienic assembly
starting at approximately $85
000 USD depending on size
dan keperluan kapasiti

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

Pakej Perkhidmatan:
• Pentauliahan & latihan pengendali
• Annual inspection & certification program
• Priority parts fulfillment guarantee

Pilihan Pembiayaan:
We work with thirdparty lenders
to offer equipment leasing structures
or extended payment terms over \[24\]
\[36\]
atau \[60\] bulan

8 Soalan Lazim

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

S2 Apakah kesan jangkaan ke atas keseluruhan penggunaan tenaga tumbuhan kami?
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