FDA منظور ٿيل ليم اسٽون مائننگ ODM ٺاهيندڙ
1. PAINPOINT driven اوپننگ
Are you managing a limestone operation where inconsistent feed size, ڇڪڻ وارو مواد, and stringent purity requirements for FDAapproved products are eroding your profitability? Operational challenges in this specialized sector directly impact compliance and the bottom line.
آلودگي جو خطرو: Noncompliant equipment materials or wear debris can introduce contaminants, risking batch rejection and regulatory scrutiny for your pharmaceutical or foodgrade calcium carbonate.
غير موثر سائز جي گھٽتائي: Standard crushers often struggle with the precise particle size distribution (پي ايس ڊي) required for highvalue applications, leading to excessive recrushing, توانائي جو ضايع, ۽ آف اسپيڪ پراڊڪٽ.
زيادتي پائڻ & سار سنڀال: The abrasive nature of limestone accelerates wear on standard machinery components, causing unplanned downtime, اعلي حصن جي متبادل خرچ, and inconsistent product quality.
Dust Control Failures: Inadequate containment during processing creates environmental, صحت, and safety hazards, while also representing a direct loss of saleable product.
How do you ensure your processing line delivers the purity, مطابقت, and reliability demanded by FDAregulated supply chains while controlling operational costs? The solution lies in purposeengineered equipment designed for this exacting application.
2. پيداوار جو جائزو: FDAApproved Limestone Processing Plant
This is a modular, integrated processing system engineered for the primary and secondary crushing, اسڪريننگ, and material handling of limestone destined for FDAregulated applications. The plant is constructed using compliant materials and designed for closedcircuit operation to minimize contamination risk.
آپريشنل ڪم فلو:
1. پرائمري ڪرشنگ & پري اسڪريننگ: Runofmine limestone is reduced by a heavyduty jaw crusher. An integrated prescreen removes fine material and foreign debris early in the process.
2. ClosedCircuit Secondary Crushing: Material is conveyed to a cone crusher operating in a closed loop with a sizing screen. This allows for precise control over the topsize product and immediate recirculation of oversize material.
3. Dedicated Fines Management & مٽي ڪنٽرول: Generated fines are captured via an integrated baghouse filtration system with FDAcompliant filter media. Captured material is conveyed to dedicated silos as saleable product.
4. Clean Material Handling: All interprocess conveyors are fully enclosed with easyclean access points. Crusher cavities and contact points are lined with certified wear materials.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for producing crushed limestone aggregates and powders for pharmaceutical excipients (USP/EP grade), foodgrade calcium carbonate (FCC), dietary supplements, and other highpurity industrial fillers.
حدون: System is designed for nonmetallic mineral processing. Feed rock must be within specified hardness (محسن اسڪيل) and maximum feed size limits. Not suitable for highly moist or claybound material without predrying or washing modules.
3. بنيادي خاصيتون
تصديق ٿيل مواد جي تعمير | ٽيڪنيڪل بنياد: ASTM/ASMEgrade 304/316L stainless steel contact surfaces & FDAcompliant polymer liners | آپريشنل فائدا: Eliminates risk of metallic contamination; ensures surface cleanability; meets audit requirements for traceable materials | ROI اثر: Reduces liability risk; prevents costly batch rejections; streamlines regulatory compliance documentation.
Precision ClosedCircuit Crushing | ٽيڪنيڪل بنياد: Hydroset or similar hydraulic adjustment on secondary crusher paired with multideck sizing screens | آپريشنل فائدا: Delivers tight control over Particle Size Distribution (پي ايس ڊي); minimizes generation of unwanted fines; allows quick adjustment for different product specs | ROI اثر: Increases yield of target fraction by up to 15%; reduces energy waste from overprocessing.
Integrated Containment & Dust Recovery | ٽيڪنيڪل بنياد: Negative pressure design with PLCcontrolled pulsejet baghouse using foodgrade filter bags | آپريشنل فائدا: تي مشتمل آهي >99.9% of process dust at source; maintains clean plant environment; recovers valuable product | ROI اثر: Turns an environmental loss into revenue; significantly reduces housekeeping labor; mitigates silica exposure risks.
Advanced Wear Protection System | ٽيڪنيڪل بنياد: Interchangeable liner panels made from highchrome white iron or ceramic composites in critical wear zones | آپريشنل فائدا: Extends service intervals by 23x compared to standard manganese steel; maintains consistent cavity geometry for stable output | ROI اثر: لباس جي حصن جي قيمت گھٽائي ٿي; reduces frequency of disruptive maintenance shutdowns.
مرڪزي پروسيس ڪنٽرول (پي ايل سي) | ٽيڪنيڪل بنياد: Siemens/AllenBradley PLC with HMI touchscreen providing amperage monitoring, CSS tracking, and interlock controls | آپريشنل فائدا: Gives operators realtime insight into plant performance; enables predictive maintenance alerts; allows repeatable setup for different products | ROI اثر: Optimizes throughput; آپريٽر جي غلطي کي گھٽائي ٿو; shortens changeover times between product grades.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | FDAApproved Limestone Plant Solution | فائدو (% سڌارو) |
| : | : | : | : |
| پيداوار جي صفائي جي ضمانت| Carbon steel contact parts with potential corrosion/contamination| Certified stainless steel & compliant liners at all product contact points| Risk mitigation from material traceability & cleanability |
| Target Fraction Yield (% جو 20 ميش +100 ميش)| ~6575% due to open circuit or basic crushing circuits| 8085% through optimized closedcircuit crushing & اسڪريننگ| +15% سراسري پيداوار ۾ اضافو |
| Wear Life in Critical Zones (ڪلاڪ)| 8001,200 hours on standard manganese steel| 2,4003,000 hours with composite liner systems| +150% وڌايل خدمت زندگي |
| Process Dust Emission (mg/Nm³)| <50 mg/Nm³ with standard baghouse| 80% reduction in particulate emission |
| توانائي جي ڪارڪردگي (kWh/ٽن)| Varies widely based on circuit design| فيلڊ ڊيٽا ڏيکاري ٿو 1012% reduction through optimized load sharing & reduced recirculating load| 1012% گھٽ مخصوص توانائي واپرائڻ |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 جي طرف 400 ٽين في ڪلاڪ (ٽي پي ايڇ), depending on feed size and target product gradation.
بجلي جي گهرج: ڪل ڳنڍيل لوڊ کان 250 kW کان 1.2 ميگاواٽ. Plant requires 480V/3Phase/60Hz power supply (ٻيا voltages موجود آهن).
مواد جي وضاحت: All productcontact surfaces are ASTM A240 Grade 316L Stainless Steel or FDAcompliant polyurethane/ceramic liners. Structural steel is primed and painted with industrial epoxy coating.
جسماني طول و عرض (عام سيٽ اپ): ماڊلر ڊيزائن. اي 150 TPH plant footprint is approximately 30m (ايل) x 15m (ڊبليو) x 12 م (ايڇ).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل. Electrical components rated for IP65 protection against dust and water ingress.
6. درخواست جا منظر
Pharmaceutical Excipient Production | چيلنج: A specialty minerals producer needed to supply USPgrade calcium carbonate but their existing plant used carbon steel screens and conveyors, creating iron oxide contamination risk during wear. Audits identified this as a critical nonconformance.| حل: Implementation of a turnkey secondary crushing & screening module from our FDAapproved limestone plant line, featuring allstainless contact surfaces and a dedicated fines recovery system.| نتيجا: Achieved full compliance with supplier quality agreements. Contaminationrelated batch rejections fell to zero within the first year of operation. The recovered ultrafine fraction opened a new revenue stream.
FoodGrade Calcium Carbonate Expansion | چيلنج: A processor aiming to enter the FCC market required a new production line that could guarantee cleanliness while achieving a very specific coarse granule profile (+16 ميش 40 ميش) at high throughput.| حل: A complete primarytotertiary processing plant was installed, emphasizing precision screening stages and total dust containment per food manufacturing facility standards.| نتيجا: The plant consistently met the stringent granule specification with <5% فرق, securing longterm contracts with major food additives distributors. Dust emissions remained below internal hygiene benchmarks.
7 تجارتي خيالات
قيمت جا درجا: Systems are configured modularly.
بنيادي جوڙجڪ: Secondary crushing/screening module with standard dust control.
بهتر ڪيل ترتيب: Full primary+secondary circuit with advanced PLC controls and extended wear packages.
ٽرنڪي ترتيب: Complete system including civil engineering support, تنصيب جي نگراني, ڪميشن ڪرڻ, ۽ آپريٽر ٽريننگ.
اختياري خاصيتون: Metal detection systems at feed point; خودڪار گريس لوڻ وارو نظام; ريموٽ مانيٽرنگ ٽيليميٽيڪس پيڪيج; acoustic enclosures for noise suppression.
سروس پيڪيجز: سالياني معائنو معاهدو; ضمانت ٿيل اسپيئر پارٽس جي دستيابي پروگرام (مثال, 24/48ڪلاڪ پهچائڻ); onsite rotor rebuild services.
فنانسنگ جا اختيار: Equipment leasing through thirdparty partners; rentaltoown programs available for qualifying projects; milestonebased project financing can be structured for large turnkey installations.
8 FAQ
1. What documentation do you provide to support FDA compliance?
We provide full Material Certificates (Mill Test Reports) for all stainlesssteel components used in product contact areas , along with Declarations of Conformity stating construction follows current Good Manufacturing Practice (cGMP) principles relevant to equipment design.
2. How does this system integrate with our existing quarry primary crusher or downstream milling circuit?
The plants are designed as skidmounted modules with standardized conveyor interfaces . Our engineering team conducts a frontend review of your existing layout feed points discharge requirements , ensuring compatibility .
3.What is the expected impact on our overall plant availability?
By design , key components feature extended wear life . Industry data from similar installations shows planned maintenance intervals can be extended by approximately onethird , contributing positively to overall equipment effectiveness OEE .
4.پيش ڪيل ڪارڪردگي جي ضمانت آهن?
ها . We offer guaranteed throughput capacity based on agreedupon feed material specifications , along with guaranteed maximum dust emission levels . These are formalized in the sales contract .
5.What operator training is included?
Comprehensive training is provided covering normal operation , حفاظتي طريقا , بنيادي مسئلو حل ڪرڻ ,and preventative maintenance tasks . Training occurs both at commissioning onsite .
6.Can we produce multiple different product grades on this system?
ها . The closedcircuit design allows adjustment via crusher setting changes screen cloth changes . Changeover procedures typically take one shift crew .
7.Do you offer ongoing technical support after commissioning?
Support includes access phone email technical assistance lifetime access updated documentation drawings optional remote diagnostic support via telematics package
