Passion Engineers Mumbai, Maharashtra

A Sample Process flow of the system

• Silo of 1 Ton (1 unit): This Silo would be mounted on the load cell and would indicate the weight of the material filled in it. A complete batch including different ingredients would be made here manually by checking the weight of each item while filling.
• Vibratory Feeder (1 unit): This Feeder would be placed each at the bottom of the Silo to feed the material in the Z Type Elevator.
• Z-Type Elevator: This would carry the material from the discharge of the Vibratory feeder and will convey it to the Mixer via the Diverter.
• Y – Diverter: This would be mounted at the outlet of Z Elevator. It would be pneumatically operated by a manual solenoid valve and would alternately feed the 2 Mixers  
• Mixer 750 Kg (Twin): This would thoroughly mix the Ingredients received from the weigh hopper. It has a 10HP main motor Mixer. The discharge valve below it is of Flap type operated by pneumatic cylinders, which while in closed condition doesn’t allow any material to get accumulated over it.
• Collection Hopper (1 Ton): This would be mounted below the 2 mixers and would take the discharge from both of the mixers
• Screw Conveyor (1 unit): This would convey the material from the outlet of the Collection Hopper and would feed at the inlet of the Bagging Station.
• Bagging Station (1 Unit): The bags of 50 Kg each would be filled here it consists of two outlets for each where the material would come alternately. While one bag is getting filled in the 1st outlet, the 2nd would be stopped and will be replaced with a new bag manually. The Weight scale is placed below the two outlets which would automatically weigh 50 Kg and then switch the discharge to the other outlet.

The complete drying plant compromises Rotary Cascade Dryer, Air Heater, Dryer Inlet Hood, Exhaust Hood, Exhaust Air Fan & Ducting and all necessary Controls.

Duty : To Dry about 750 Kg/hr. of Chilly Flakes from approximately 20% initial moisture to 8-10 % final moisture.

Dryer Drum: 3 Ft Diameter X 28 Ft. long dryer drum fabricated in Stainless Steel plate SS-304, with internal flights and lifters fabricated and bolted to Stainless steel angle sections welded to the shell plates to ensure adequate contact between the drying air and the material being processed. The drum is fitted with two cast or forged steel tires, mounted on carbon steel spacer blocks fitted to a reinforcing band. The tires run on four cast or forged steel support rollers shrunk to fit on steel shafts with shaft-mounted spherical roller bearing Plummer blocks. A segmental cast steel chain ring is fitted around the periphery of the dryer drum.

Support Frames : The complete dryer drum assembly is supported on two fabricated carbon steel roller support frames, the feed ends support frame carrying the locating roller assemblies. Both roller support frames are fitter with safety guards.

Drum Drive : The dryer drum is driven by a T.E.F.C. electric motor through a V-belt drive, gearbox, pinion, and chain to the drum drive chain wheel. The motor, gearbox, V-belt, etc. are mounted on a fabricated carbon steel baseplate. All drives are completely enclosed in suitable safety guards.

Air Heater : The drying air is provided using Electrical Operated, firing into a refractory lined carbon steel combustion chamber connected to the dryer inlet end hood. It can also be operated with an Electrical Heater of 30 KiloWatts rating.

Inlet End Hood : The inlet end of the drum is enclosed with a Stainless steel fabricated enclosure, complete with a labyrinth seal and stainless steel material inlet chute. The inlet hood is supported by a suitable rolled steel section support structure.

Outer End Hood: The outer end of the drum is enclosed with a carbon steel fabricated hood complete with an inspection access door, and exhaust air outlet chute. A labyrinth-type flexible seal is fitted to the rear hood plates around the drum opening. The outlet end is supported by a suitable rolled steel section support structure.

Exhaust Air Fan : The exhaust air is drawn from the dryer by a centrifugal fan, complete with an electric motor, V-belt drive, and drive guard.

Exhaust Air Ducting : The exhaust air from the dryer is conveyed via a Stainless steel duct from the outlet end hood to the cyclone and from the cyclone to the exhaust fan. A manually operated butterfly-type valve damper is fitted in the exhaust duct between the cyclone and the exhaust fan.

Control System : Inlet air temperature is measured using a thermocouple located in the inlet end hood connected to a temperature indicator/recorder. Exhaust air temperature is measured by a thermocouple located in the exhaust air duct connected to a temperature indicator/recorder. The Electrical output is controlled using a suitable Thermostat via a suitable transmitter from either of the two temperature indicator controllers. All necessary motor control gear, relays, overloads, etc. and temperature indicators/recorders are housed in a carbon steel control cabinet which will be prewired for correct sequential start-up and operation of the plant.

The complete drying plant compromises Rotary Cascade Dryer, Air Heater, Dryer Inlet Hood, Exhaust Hood, Exhaust Air Fan & Ducting and all necessary Controls.

Duty : To Dry about 750 Kg/hr. of Chilly Flakes from approximately 20% initial moisture to 8-10 % final moisture.

Dryer Drum : 3 Ft Diameter X 28 Ft. long dryer drum fabricated in Stainless Steel plate SS-304 , with internal flights and lifters fabricated and bolted to Stainless steel angle sections welded to the shell plates to ensure adequate contact between the drying air and the material being processed. The drum is fitted with two cast or forged steel tyres, mounted on carbon steel spacer blocks fitted to a reinforcing band. The tyres run on four cast or forged steel support rollers shrunk fit on steel shafts with shaft mounted spherical roller bearing plummer blocks. A segmental cast steel chain ring is fitted around the periphery of the dryer drum.

Support Frames: The complete dryer drum assembly is supported on two fabricated carbon steel roller support frames, the feed end support frame carrying the locating roller assemblies. Both roller support frames are fitter with safety guards.

Drum Drive: The dryer drum is driven by a T.E.F.C. electric motor through V-belt drive, gearbox, pinion and chain to the drum drive chain wheel. Motor, gearbox and V-belt, etc. are mounted on a fabricated carbon steel baseplate. All drives are completely enclosed in suitable safety guards.

Air Heater : The drying air is provided by means of Electrical Operated, firing into a refractory lined carbon steel combustion chamber connected to the dryer inlet end hood. It can also be operated with Electrical Heater of 30 KiloWatts rating.

Inlet End Hood :The inlet end of the drum is totally enclosed with a Stainless steel fabricated enclosure, complete with labyrinth seal. and stainless steel material inlet chute. The inlet hood is supported by a suitable rolled steel section support structure.

Outer End Hood : The outer end of the drum is totally enclosed with a carbon steel fabricated hood complete with inspection access door, exhaust air outlet chute. A labyrinth type flexible seal is fitted to the rear hood plates around the drum opening. The outlet end is supported by a suitable rolled steel section support structure.

Exhaust Air Fan : The exhaust air is drawn from the dryer by a centrifugal fan, complete with electric motor, V-belt drive and drive guard.

Exhaust Air Ducting : The exhaust air from the dryer is conveyed via a Stainless steel duct from the outlet end hood to the cyclone and from the cyclone to the exhaust fan. A manually operated butterfly type valve damper is fitted in the exhaust duct between the cyclone and exhaust fan.

Control System : Inlet air temperature is measured by means of a thermocouple located in the inlet end hood connected to a temperature indicator/recorder. Exhaust air temperature is measured by a thermocouple located in the exhaust air duct connected to a temperature indicator/recorder. The Electrical output is controlled by means of a suitable Thermostat via a suitable transmitter from either of the two temperature indicator controllers. All necessary motor control gear, relays, overloads, etc. and temperature indicators/recorders are housed in a carbon steel control cabinet which will be prewired for correct sequential star-up and operation of the plant.