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

1. KHAI THÁC ĐIỀU KHIỂN 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?

Rủi ro ô nhiễm sản phẩm: 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.
Loại bỏ tiền phạt không hiệu quả & Product Degradation: Inconsistent vibration or poor screen deck design leads to blinding, thông lượng giảm, and an inability to precisely separate fines. This results in offspec product and wasted yield.
Thời gian ngừng bảo trì quá mức: Standard industrial screens are not designed for the rigorous hygiene standards required. Vệ sinh, điều tra, and part replacement are timeconsuming, directly impacting your plant’s operational availability.
Ăn mòn & 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.

Câu hỏi trung tâm là: how do you achieve highcapacity, reliable particle sizing while guaranteeing a contaminantfree process that meets stringent regulatory audits?

2. TỔNG QUAN SẢN PHẨM

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.

Quy trình hoạt động:
1. Nguồn cấp dữ liệu được kiểm soát: Prescreened coke is introduced via an FDAcompliant feed chute onto the first screen deck.
2. Tách chính xác: 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 (người trung gian) 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.

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

3. TÍNH NĂNG CỐT LÕI

Hygienic ClampTogether Assembly | Cơ sở kỹ thuật: FDAcompliant 304/316L stainless steel construction with polished finishes | Lợi ích hoạt động: Eliminates bolt threads and lap joints that trap particles; enables rapid disassembly for inspection and cleaning | Tác động ROI: Reduces sanitation labor time by up to 60% versus bolted designs, minimizing production line changeover windows.

Sealed Vibration Mechanism | Cơ sở kỹ thuật: Dusttight vibrator motor housings with FDAaccepted lip seals; optional internal air purge system | Lợi ích hoạt động: Prevents lubricant ingress into product zone and protects bearings from corrosive dust | Tác động ROI: Kéo dài tuổi thọ vòng bi lên 23 lần, eliminating a primary source of product contamination and unplanned downtime.

QuickChange Screen Deck System | Cơ sở kỹ thuật: Tensioned polyurethane or stainless steel mesh decks with sanitary attachment rails | Lợi ích hoạt động: Allows a single operator to replace screen panels in under 10 minutes without tools | Tác động ROI: Increases plant flexibility for different product grades and restores full capacity faster after maintenance.

Sanitary Frame Design | Cơ sở kỹ thuật: Continuous welds polished to a 4 finish; coved corners; integrated CIP spray ball ports | Lợi ích hoạt động: Prevents material buildup and bacterial growth; supports validated cleaning protocols | Tác động ROI: Ensures continuous compliance with FDA audits, avoiding costly production halts for deep cleaning.

Optimized Vibration Dynamics | Cơ sở kỹ thuật: Computermodeled vibratory motion tuned for coke particle flow characteristics | Lợi ích hoạt động: Minimizes particle degradation (sự hao mòn) while maximizing screening efficiency and throughput per square foot of deck area | Tác động ROI: Improves yield of onspec product by 38% compared to poorly tuned industrial screens.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Industry Standard Screen Assembly | Our FDAApproved Coke Vibration Screen Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Sanitation Compliance Time | Manual scrubbing of complex assemblies (812 giờ) | Validated CleaninPlace (CIP) procedure (100% Sự cải tiến |
| Hiệu quả sàng lọc (Sự chính xác) | ~8590% efficiency on fine meshes (<40 lưới) | Nhất quán 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. THÔNG SỐ KỸ THUẬT

Dung tích & Đánh giá: Người mẫu từ 20 TPH đến 150 TPH throughput capacity for coke bulk density (~0,50,8 tấn/m³). Được thiết kế cho 24/7 hoạt động liên tục.
Yêu cầu về nguồn điện: Vibrator motors from 2 x 2 HP tới 2 x 10 HP depending on model; standard supply at 460V/60Hz/3Ph; điện áp khác có sẵn.
Thông số vật liệu: 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.
Kích thước vật lý: Biến theo mô hình; typical footprint range from \(3m L x \(1\).8m W\) lên đến \(6m L x \(2\).5m W\). Height typically under \(2\).5m including feed hopper.
Phạm vi hoạt động môi trường: Ambient temperature range of \(0°C\) ĐẾN \(40°C\) (\(32°F\) \(104°F\)). Khả năng chịu ẩm lên tới \(95\%\) không ngưng tụ.

6. KỊCH BẢN ỨNG DỤNG

[FoodGrade CPC Producer] Thử thách: 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] Thử thách: Producing highvalue modified carbon required separating ultrafine particles (\(5\%\) thế hệ tiền phạt).

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

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

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

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

[FoodGrade CPC Producer] Kết quả: Achieved consistent audit readiness

[Specialty Carbon Manufacturer] Kết quả: Achieved target purity specifications

[MultiGrade Coke Facility] Kết quả: Enabled simultaneous production

7 CÂN NHẮC THƯƠNG MẠI

Our solutions are offered in three primary tiers:

1\. Cấp hệ thống cơ sở
Includes core hygienic assembly
starting at approximately $85
000 USD depending on size
và yêu cầu về năng lực

Tính năng tùy chọn:
• Advanced CIP automation package
• Explosionproof motor ratings
• Integrated metal detection systems
• Custom discharge spouting configurations
• Remote monitoring sensors

Gói dịch vụ:
• Vận hành thử & đào tạo điều hành
• Annual inspection & certification program
• Priority parts fulfillment guarantee

Tùy chọn tài chính:
We work with thirdparty lenders
to offer equipment leasing structures
or extended payment terms over \[24\]
\[36\]
hoặc \[60\] tháng

8 Câu hỏi thường gặp

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 Tác động dự kiến ​​đến mức tiêu thụ năng lượng tổng thể của nhà máy là gì?
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