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

1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

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?

Риск загрязнения продукта: 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.
Неэффективное удаление штрафов & Product Degradation: Inconsistent vibration or poor screen deck design leads to blinding, снижение пропускной способности, and an inability to precisely separate fines. This results in offspec product and wasted yield.
Чрезмерное время простоя при техническом обслуживании: Standard industrial screens are not designed for the rigorous hygiene standards required. Очистка, инспекция, and part replacement are timeconsuming, directly impacting your plant’s operational availability.
Коррозия & 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 (СИП) procedures ineffective.

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

2. ОБЗОР ПРОДУКТА

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

Операционный рабочий процесс:
1. Контролируемая подача: Prescreened coke is introduced via an FDAcompliant feed chute onto the first screen deck.
2. Точное разделение: 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 (посредничество) 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.

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

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Hygienic ClampTogether Assembly | Техническая основа: FDAcompliant 304/316L stainless steel construction with polished finishes | Операционная выгода: Eliminates bolt threads and lap joints that trap particles; enables rapid disassembly for inspection and cleaning | Воздействие на рентабельность инвестиций: Reduces sanitation labor time by up to 60% versus bolted designs, minimizing production line changeover windows.

Sealed Vibration Mechanism | Техническая основа: Dusttight vibrator motor housings with FDAaccepted lip seals; optional internal air purge system | Операционная выгода: Prevents lubricant ingress into product zone and protects bearings from corrosive dust | Воздействие на рентабельность инвестиций: Увеличивает срок службы подшипников в 23 раза., eliminating a primary source of product contamination and unplanned downtime.

QuickChange Screen Deck System | Техническая основа: Tensioned polyurethane or stainless steel mesh decks with sanitary attachment rails | Операционная выгода: Allows a single operator to replace screen panels in under 10 minutes without tools | Воздействие на рентабельность инвестиций: Increases plant flexibility for different product grades and restores full capacity faster after maintenance.

Sanitary Frame Design | Техническая основа: Continuous welds polished to a 4 finish; coved corners; integrated CIP spray ball ports | Операционная выгода: Prevents material buildup and bacterial growth; supports validated cleaning protocols | Воздействие на рентабельность инвестиций: Ensures continuous compliance with FDA audits, avoiding costly production halts for deep cleaning.

Optimized Vibration Dynamics | Техническая основа: Computermodeled vibratory motion tuned for coke particle flow characteristics | Операционная выгода: Minimizes particle degradation (потертость) while maximizing screening efficiency and throughput per square foot of deck area | Воздействие на рентабельность инвестиций: Improves yield of onspec product by 38% compared to poorly tuned industrial screens.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Industry Standard Screen Assembly | Our FDAApproved Coke Vibration Screen Solution | Преимущество (% Улучшение) |
| : | : | : | : |
| Sanitation Compliance Time | Manual scrubbing of complex assemblies (812 часы) | Validated CleaninPlace (СИП) procedure (100% Улучшение |
| Эффективность скрининга (Точность) | ~8590% efficiency on fine meshes (<40 сетка) | Последовательный 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. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Емкость & Рейтинг: Модели из 20 ТПХ до 150 TPH throughput capacity for coke bulk density (~0,50,8 т/м³). Предназначен для 24/7 непрерывная работа.
Требования к питанию: Vibrator motors from 2 х 2 HP в 2 х 10 HP depending on model; standard supply at 460V/60Hz/3Ph; доступны другие напряжения.
Характеристики материала: 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.
Физические размеры: Переменная в зависимости от модели; typical footprint range from \(3m L x \(1\).8m W\) до \(6m L x \(2\).5m W\). Height typically under \(2\).5m including feed hopper.
Экологический рабочий диапазон: Ambient temperature range of \(0°C\) к \(40°C\) (\(32°F\) \(104°F\)). Допуск влажности до \(95\%\) неконденсирующийся.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

[FoodGrade CPC Producer] Испытание: 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] Испытание: Producing highvalue modified carbon required separating ultrafine particles (\(5\%\) начисление штрафов).

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

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

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

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

[FoodGrade CPC Producer] Результаты: Achieved consistent audit readiness

[Specialty Carbon Manufacturer] Результаты: Achieved target purity specifications

[MultiGrade Coke Facility] Результаты: Enabled simultaneous production

7 КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Наши решения предлагаются на трех основных уровнях.:

1\. Базовый уровень системы
Includes core hygienic assembly
starting at approximately $85
000 USD depending on size
и требования к мощности

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

Пакеты услуг:
• Ввод в эксплуатацию & обучение операторов
• Annual inspection & certification program
• Priority parts fulfillment guarantee

Варианты финансирования:
We work with thirdparty lenders
to offer equipment leasing structures
or extended payment terms over \[24\]
\[36\]
или \[60\] месяцы

8 Часто задаваемые вопросы

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 Каково ожидаемое влияние на общее энергопотребление завода??
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