Processing February 2012

February 2012
SOLUTIONS FOR THE PROCESS INDUSTRIES
Mixing & Size Reduction

Mixing and Dispersing Batching System
The Standard Production Plant (SPP) is a multi-purpose mixing and dispersing batching system designed to emulsify, homogenize or blend virtually any material. The vessel, recirculation piping, valves, controls and dual in-line mixing unit are included. Design of the SPP eliminates the need for additional equipment such as circulating and transfer pumps. Two components in the system an integral agitator and high-shear mixing unit combine to provide the most complete mixing, with the option to add powders without the need of vacuum. The SPP construction is limited to features necessary for the process as it relates to mixing results. For more information on Mixing & Size Reduction, go to page 8.
Featured Columnist
Try as we might, instead of improving communication, contemporary society still seems compelled to make it more difcult. The use of buzz words, acronyms and other letter abbreviations is increasing at a dramatic pace. Frequently, the creation of a new series of acronyms or other letter-type abbreviations is simply an attempt to make a concept appear substantially different from previously known data, when in fact, its the same old stuff with a different name. Pump expert Ross Mackay discusses effective communication in this exclusive guest column. To read the column, turn to page 18.
Rotary Feeder for Bulk Material Handling

The MD Series of rotary feeder valves from ACS Valves immediately contributes tangible operating efciency advantages and long-term production and maintenance savings. It is constructed with an 8-vane rotary valve that ensures proper pressure sealing at the inlet and outlet ange. The optimal seal produced by an MD Series rotary feeder can reduce compressed air loss by up to 28 CFM/year, according to the manufacturer. For more information on Powder & Bulk Solids, turn to page 38.
IKA Works, Inc. 800-733-3037, www.ikausa.com

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Featured Article
Biosphere Industries, a manufacturer of biodegradable packaging and biodegradable bakeware, needed a highly accurate ingredient batching system to help meet its sustainability goals. The company interviewed several candidate vendors and, on the basis of speed, repeatability, lead time for completion and cost, selected a turnkey automated batching system. To read about this success story, turn to page 20.
ACS Valves www.acsvalves.com

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Work Light Strip

The WLS28 delivers a versatile lighting solution, featuring a robust, yet small prole, metal housing and is available in various lengths from 145mm to 1130mm, while maintaining the same narrow width of 28mm for all models. Extremely bright LEDs emit an even pattern of light, casting no shadows. The WLS28 also provides signicant cost- and timesaving attributes in the form of energy efciency and installation simplicity. For more information about Plant Maintenance & Safety, go to page 32.
Next Generation Slurry Pump

The new Goulds XHD Extra Heavy Duty World-Class Lined Slurry Pump can handle the heaviest slurry under the toughest conditions, according to the manufacturer. The new pump is designed to be maintained even while running, and to require less downtime for service procedures with parts that are more accessible and adjustable than in other slurry pumps. For more information on Pumps & Seals, go to page 14.
ITT Goulds www.gouldspumps.com

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Banner Engineering www.bannerengineering.com
www.ProcessingMagazine.com
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Table of Contents
6 MAKE: An American Manufacturing Movement
The Council on Competitiveness, a Washington, D.C.-based nonprot, non-partisan organization, is seeking to re-establish manufacturing as a cornerstone of American independence.
February2012 volume25,number02
12 Horizontally-Split Centrifugal Compressor Conguration

Rotating equipment engineer Amin Almasi addresses the optimal conguration for horizontally-split centrifugal compressors.
20 Sustainable Food Packaging Solutions

A manufacturer of biodegradable packaging and bakeware selected a turnkey automated batching system for its speed, repeatability, lead time for completion and cost.
26 Better Safe Than Sorry!
Based on the harmless appearance of a bagel, its hard to imagine that making these popular treats may, in fact, pose an occasional hazard. But its true, according to ofcials at a bread manufacturing company based in Toronto.
30 Getting Serious About Lubrication
Despite millions of dollars spent to improve machine condition and reliability, improper lubrication is still cited as the primary cause of premature equipment failure today.
34 The Importance of Thorough Mixing

Glass manufacturer utilizes an abrasion-resistant rotary mixer to blend ingredients rapidly.
4 8
Editors Column Mixing & Size Reduction
A technical resource for mixing and blending from Charles Ross & Son is featured.
14 Pumps & Seals 28 Food Equipment
Spear-tip piercing pH electrodes are among the spotlighted products in this section.
29 Plant Automation 32 Plant Maintenance & Safety 38 40 41 43 44 Powder & Bulk Solids Tanks & Vessels Info Center Classieds Index
February 2012www.ProcessingMagazine.com
A line of industrial sounders from Pfannenberg is spotlighted.
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Editors Desk
Bringing U.S. Manufacturing Back: A Blueprint for the Future?
In his State of the Union address before Congress on Jan. 24, President Obama laid out a vision for revitalizing the American economy with an emphasis on U.S. manufacturing. In particular, the president said he wants to implement a minimum tax for multinational companies, which would help provide tax breaks for companies that create jobs in the U.S. He sweetened the pot by calling for bigger tax breaks for high-tech manufacturers and nancial assistance for companies that choose to relocate to struggling communities. My message is simple, Obama said. Its time to stop rewarding businesses that ship jobs overseas, and start rewarding companies that create jobs right here in America. The president also announced the creation of a Trade Enforcement Unit, which is tasked with making sure that no foreign company has an unfair advantage over U.S. manufacturers, and encouraged private sector companies to partner with community colleges to train new workers. Of course, this was not the rst time Obama has campaigned for American manufacturing. Two weeks prior to the State of the Union, Obama hosted a forum at the White House to discuss the trend of insourcing. During the Insourcing American Jobs forum, the president met with leaders from 14 companies including Ford, Dupont, Intel and Siemens to lay out his plan for increasing investment in the United States and to learn what incentives corporations would need to bring jobs back to this country. I dont want America to be a nation thats primarily known for nancial speculation and racking up debt buying stuff from other nations, Obama said. I want us to be known for making and selling products all over the world stamped with three proud words: Made in America. And we can make that happen. While Obamas interest in re-establishing the U.S. as a manufacturing superpower is refreshing, it remains to be seen whether the president is serious about enacting these reforms or if he is simply pandering to blue collar Democrats. Unfortunately, the chances of getting any major legislative initiatives passed before the November election are slim at best. What do you think about the presidents proposals to invest in American manufacturing? How will it affect your business? Send me your thoughts at nphillips@grandviewmedia.com.
Publisher, Mike Wasson Ph: 973-539-7715, Email: mikew@grandviewmedia.com Managing Editor, Nick Phillips Email: nphillips@grandviewmedia.com Associate/Web Editor, ChristyUnderwood Email: christy@grandviewmedia.com Art Director, JamesArmstrong Email: jarmstrong@grandviewmedia.com Graphic Designer, Brandon Watkins Email: brandon@grandviewmedia.com Marketing Manager, Mary Beth Timmerman Email: marybeth@grandviewmedia.com Advertising Sales Assistant, HaleyMartin Email: hmartin@grandviewmedia.com Administrative Team: General Manager, BarryLovette Vice President of Operations, BrentKizzire Vice President of Marketing, HankBrown Vice President of Finance, BradYoungblood Director of Circulation & Fulllment, Delicia Poole Circulation Manager, Electronic Products, StacieTubb
PROCESSING (Pub.#ISSN 0896-8659) PROCESSING Magazine is published monthly by Grand View Media Group. Editorial and Executive Ofices: 200 Croft Street, Ste 1, Birmingham, AL 35242. Periodicals postage paid at Birmingham, AL & additional mailing ofices. Canada Post: Publications Mail Agreement #40612608. Canadian Returns to be sent to: Bleuchip International, P.O. Box 25542, London, ON N6C 6B2. POSTMASTER: Send address changes to PROCESSING Magazine, PO BOX 2174, Skokie, IL 60076-7874. SUBSCRIPTIONS: Non-qualiied domestic subscriptions: one year, $57; two year, $99; single issue, $10. Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail subscription: one year, $203; two year, $355. Grand View Media Group, 2012. PROCESSING Magazine assumes no responsibility for validity of claims in items reports.
NickPhillips, Managing Editor nphillips@grandviewmedia.com Follow me on Twitter @ ProcessingMag
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Reader Advisory Board

RobertJ.Bockserman,President, Conatech PeterS.Cartwright,President, Cartwright Consulting Co. BarryCharnay,President & CEO, Whisper Ingredients Inc. KenDelafrange,President, Jadee Inc. DonGraham,President, Graham Sanitary Design Consulting, Ltd. StanleyHerzog,President, Princeton Process Technology Consultants B.GeorgeKniazewyz,President, Renovare EricLanger,President, BioPlan Associates EdMarshall,President, Maintenance Management Technologies DaveC.Orlowski,President & CEO, INPRO/SEAL Company JohnStansield,Plant Manager, Accelerated Curing Inc. Dr.JesseYoder,President, Flow Research
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February 2012 www.ProcessingMagazine.com
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MAKE: An American Manufacturing Movement

Non-Proit Organization Seeks to Re-establish Manufacturing as a Cornerstone of American Independence
The Council on Competitiveness, a Washington, D.C.-based non-prot, non-partisan organization, recently celebrated its 25th anniversary during the National Manufacturing Competitiveness Summit on Dec. 7-8, 2011. The Council, whose membership consists exclusively of corporate CEOs, presidents of universities and heads of labor unions, provides policy recommendations to make America more competitive in the international marketplace. Under the leadership of Council President and CEO Deborah L. Wince-Smith, Council Chairman and Deere & Company Chairman and CEO Samuel Allen and a steering committee of 60 CEOs, university presidents, labor leaders and laboratory directors, MAKE: An American Manufacturing Movement was released to Congress, the White House and all 50 governors on Dec. 8, 2011. Outlining the ways in which the U.S. can maintain and grow the domestic manufacturing base, the recommendations are the result of hundreds of interviews conducted over nearly three years by Deloitte, as well as dozens of dialogues where Council members and national leaders came together to discuss specic manufacturing topics. MAKE argues that manufacturing is a cornerstone of American independence, economic prosperity and national security that must not be surrendered. Americans can no longer afford to allow their formidable innovation and creativity machine to fuel production in other countries and must capture a greater share of the benets of American ingenuity. Our national economic portfolio requires a healthy and growing manufacturing sector to meet the grand macro-economic problems we face. The image of manufacturing as dumb, dirty, dangerous and disappearing is far from accurate. Today, manufacturing is smart, safe, sustainable and surging. The key challenges and solutions outlined in MAKE include: 1. Challenge: Fueling Investments in the Innovation and Production Economy from Start-up to Scale-up Solution: Enact scal reform, transform tax laws, regulations and other structural costs to spur investment, ramp up production, capitalize growth companies and create skilled jobs. 2. Challenge: Expanding U.S. Exports, Reducing the Trade Decit, Increasing Market Access and Responding to Foreign Governments Protecting Domestic Producers Solution: Create fair and open global markets for U.S. goods and services to reduce the trade decit and increase exports as a percentage of GDP. 3. Challenge: Harnessing the Power and Potential of American Talent to Win the Future Skills Race Solution: Prepare the next generation of innovators, researchers and highly-skilled workers. 4. Challenge: Transforming the Industrial Base to Smart Manufacturing and Innovation Networks to Spur Next-Generation Productivity Solution: Create national advanced manufacturing networks and partnerships, prioritize R&D investments and deploy new tools, technologies and facilities. 5. Challenge: Optimizing and Integrating Next Generation Supply Networks with Advanced Logistics Solution: Develop and deploy smart, sustainable and resilient energy, transportation, production and cyber infrastructures. MAKE is available for free download at the Councils website at www.compete.org.
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Technical Resource for Mixing and Blending
Process engineers and R&D scientists have a new technical resource for their mixing and blending related questions at the Charles Ross & Son Company website. The Ross Mixing Technology Insights provide many useful tips and techniques on dispersion, dry blending, emulsication, homogenization, particle size reduction, high viscosity mixing, sub-surface powder induction, sanitary mixing and other topics. Each two-page bulletin includes a sample application or mixer installation from various industries.
Automated Bulk Material Mixing System

Designed specically for fully automated introduction, transfer, mixing and blending of multiple, sluggish materials, this NBE integrated mixing system produces such homogenous blends that downstream production scrap is virtually eliminated, according to the manufacturer. An NBE lift-and-seal gaylord discharge system, with a dust-tight, custom discharge hood, introduces the material to the transfer bin. An integrated agitator and vacuum pump transfer system supply material to the high-volume material mixer. Within the mixer, an auger mixes material in a 10-gauge mix tube. In-feed scoop blades at the base of the mixing auger, and broad-throw dispersion paddles at the top ensure a homogenous and consistent blend supply to downstream processes.
Multi-Cage Mill
The Stedman H Series Multi-Cage Mill is available in 2:4- or 6-row design and in four sizes up to 250 TPH. The design features also include Air Cannons, Heaters and Hydraulic Ram. The Air Cannons are mounted at the intake and discharge to help prevent build-up of wet sticky material, while the heaters are also installed on the grinder housing to retard buildup of wet material. The Hydraulic Ram eliminated the gear head motor and rack & pinion that were used on other Stedman cage mills, now costing less to maintain, according to the manufacturer. The cage mill is a selective crushing, controlled-impact, multi-cage mill designed for sizing minerals and agglomerates, whole grains, chemical, ores and many other materials.
Charles Ross & Son Company

www.mixers.com/insights-new.asp
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Stedman
www.stedman-machine.com
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National Bulk Equipment Inc.

www.nbe-inc.com
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Upgraded Mixer Gears Deliver Quieter Operation
Neptune Mixer Company, a division of the Neptune Chemical Pump Co., has made a commitment to providing mixers that offer the longest service life when compared to competitive brands, according to the manufacturer. This longevity is designed into the product through the use of steel helical gears, high-quality bearings and high-grade lubricant. Recent feedback from customers highlighted an opportunity for Neptune to reduce the perceived sound levels being emitted from the gear-train on several of its mixer lines. Neptune worked closely with its gear supplier to optimize the gear-tooth prole by increasing the American Gear Manufacturers Association (AGMA) Quality Class from a level 6 to a level 9, resulting in tighter manufacturing tolerances on the mesh and backlash, as well as an improved running-surface nish. This upgraded, quieter gear operation was incorporated on Neptune mixers that went to market in September 2011.
Variable Flow Static Mixer

The Westfall Model 2900 Variable Flow Static Mixer optimizes mixing and minimizes head loss by employing two in-line wafertype mixers, one xed and one variable, which adjust incrementally to maintain constant head loss. Providing consistent mixing over a 20:1 turndown ratio, this mixer reduces overall system head loss at high ow rates and permits the use of smaller pumps, according to the manufacturer. Saving energy and pump wear-and-tear, the Westfall Model 2900 Variable Flow Static Mixer is available in sizes from 3/8-inch to 120-inch I.D. Separated by a distance equal to two pipe diameters; as the ow velocity increases, the variable mixer opens to reduce excessive head loss. The xed mixer has a 0.9 Beta ratio and the variable mixer has a 0.7 Beta ratio.
Neptune Mixer Company

www.neptune1.com
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Westfall Manufacturing Company

www.westfallmfg.com
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Impeller Designed to Prevent Fibrous Material Buildup

The new Chemineer RL-3 impeller is designed to prevent brous material buildup on the rotating impeller of agitators. In blending and solids suspension applications where the uid contains brous material, the resulting buildup on the agitators impeller can deteriorate performance. The Chemineer RL-3 Ragless Impeller prevents buildup to eliminate maintenance costs and downtime, increase performance and extend the service life of the agitator, according to the manufacturer.
Chemineer
www.chemineer.com
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12
Compressors
Horizontally-Split Centrifugal Compressor Conguration and Driver Selection
Amin Almasi
Lead Rotating Equipment Engineer at WorleyParsons
Compressor Conguration
For low- and medium-pressure applications, horizontally-split casings are common. Maintenance of a horizontally-split compressor is very simple and straightforward as the rotor is removed without disturbing the impellers. Horizontally-split casing major maintenance is much simpler with downward piping connections because there is no need to disturb the pipework when opening the casing. Inter- and after- coolers, as well as other auxiliaries (such as vacuum condensers for steam turbine drivers), can be conveniently located below the operating oor. As an indication, a horizontallysplit compressor is applied below around 40 Barg. However, this limit depends also on ow and gas compositions. For high capacity machines, a horizontally-split compressor is used for below 25 Barg. The pipe loads imposed on a casing should be limited. API 617 species nozzle load limits around 1.85 times NEMA SM23. However, some purchasers ask for higher loads, even as high as four times NEMA SM23, to make piping design easier. For some very large refrigeration compressors due to very large piping seizes and considerable temperature differences even ve times NEMA SM23 may be specied. These high loads may not be recommended by some engineers and API values could usually be considered as optimum selection. Vendors generally design process compressor models
Centrifugal compressors do not exhibit the internally induced shaking forces and complex pulsation problems of reciprocating compressors, and therefore do not need the same massive foundation and valve (or unloader) repairs. As plant sizes increase, the pressure to improve reliability is very high because of the large economic impact of a nonscheduled shutdown. In many modern process plants, nonscheduled shutdown impact is comparable to the long-term impact of a small decrease in efciency. Run time between centrifugal compressor overhauls currently is around four years or more. Six year run times are not unusual, and eight years or more are also reported. Centrifugal compressors, because of their simplicity, reliability, light-weight and compact design, have become much more popular for use in process plants. Centrifugal compressors have been applied in an approximate range of 2000 m3/h to 400,000 m3/h. Centrifugal compressors are available somewhat outside this range, but have problems competing because other more efcient compressors are available for above and below this range.
based on API. There is often doubt whether all necessary modications will be implemented by vendors for higher piping load values (with respect to long-term component life expected). But in some projects there is no way to ensure proper piping design and avoid expansion joints except by using higher nozzle load limits. When applications are more complex than can be accommodated by a single-case compressor, multiple cases can be used. A popular conguration is the tandem-driven series arrangement using a common driver. Gear units may be included in the compressor train, either between cases or between the driver and the compressors. The maximum number of compressor casings is usually limited to three. Longer, tandemdriven series connected compressor trains tend to encounter specic speed problems. In the longer trains, the double ow arrangement can be useful (for the rst stage) in permitting more casings to run at the same speed. At the inlet, where ow is highest, the gas stream is divided into parallel streams and the volume is reduced to a value within the specic speed capability of a single ow compressor. The alternative is the use of a speed increasing gear unit between compressor bodies to permit the ow matching of down-stream stages. When longer trains are needed, the cases are grouped with several individual drivers, maintaining the series ow concept.
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Driver Selection
Historically, the most popular drivers for centrifugal compressors have been steam turbines, which are still common drivers of centrifugal compressors in some process plants. Generally standard, compact and reliable steam turbine designs are available with reasonable cost for mechanical drives. Electric motor drives, with the exception of very large units with high inlet ows, require that a step-up gear is used. Because fossil fuel can be more efciently converted to electricity in large central generating stations, the costs of electrical energy for motors become such that to displace the more convenient steam turbines. The electric motor received a high degree of attention in modern process plants. Large electric drivers using variable frequency conversion are very popular. Initial cost may be prevented with universal acceptance of the variable frequency. However, it is a common solution for medium and large machines. Electric motors, whether speed-controlled or not, are either induction or synchronous in design. Size and plant electric system requirements set parameters for motor selection. Synchronous motors normally receive consideration only for the large drivers, with the individual plant setting the minimum size at which the synchronous machine is used. Motor drives shall conform to proper standards such as API 541 or API 546, as applicable (or for small motor IEEE 841). For motors, special consideration shall be given to the starting conditions and effects of pulsating torque. Also interaction effects with the transmission system and gear unit when variable frequency drive motors used are important. A gas turbine is selected as a compressor driver based on available fuel and plant specic requirements. It should be understood that gas turbines are relatively standardized even though they cover a wide range of power and speed. They are not custom engineered to the specic application for a power and speed match. The speeds of gas turbines are standard for a given frame. Sometimes the output speed of the gas turbine can be considered to design an efcient compressor. If not, an intermediate gear will be needed. It adds the complication of another piece of equipment, subsequently higher capital cost and potential decreased reliability. This gear unit also inherently has a high pitch line velocity making for one of the difcult applications. If exhaust heat recovery or regeneration is used, the efciency of the gas turbine is quite attractive. Drivers generally should be sized to deliver continuously not less than 110 percent of the maximum power required by the centrifugal compressor. Sometimes this margin may increase to 15 percent. Advanced technologies have been used to provide maintainable, exible and compact process horizontally-split centrifugal compressors. Worldwide installed capacity and horsepower of centrifugal compressors in process industries are more than other compressor types. Welldesigned centrifugal compressors have a high reliability and they are favorites to install without spare. Amin Almasi is lead rotating equipment engineer at WorleyParsons, Brisbane, Australia. He specializes in rotating machines including centrifugal, screw and reciprocating compressors, gas turbines, steam turbines, engines, pumps, subsea, offshore rotating machines, LNG units, condition monitoring and reliability.
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14
Pumps & Seals

Sanitary Pumps
Moyno Sanitary Pumps are ideal for any application where bacteria and contamination must be avoided and/or frequent clean-up is required, according to the manufacturer. Featuring standard mechanical seals, all 150 standard models meet 3A sanitary requirements with no modications necessary. In addition, a combination close-coupled/ open throat design is offered in a standard model.
Moyno, Inc.
www.moyno.com
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Customized Solution for Exothermic Reactions

KNF N0150 diaphragm pumps can now be customized with water-cooled heads to prevent pump overheating in process applications where exothermic reactions from helium, xenon and other gases may produce excessive heat and potentially shorten pump service life. This powerful pump is designed to deliver the highest ow rate of any electrically-operated diaphragm pump, according to the manufacturer. The pump operates without oil to eliminate risk of medium contamination and can be equipped with a double-diaphragm system for increased safety, which is critical when handling particularly dangerous gases.
KNF Neuberger Inc.

www.KNFprocess.com
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Air-Operated Double-Diaphragm Pump Technology

Wildens Advanced Series Metal AirOperated Double-Diaphragm (AODD) Pump technology features the operational advantages necessary to overcome the challenges in the ever-evolving, oftentimes difcult operating conditions found in paint and coatings manufacture. Wildens Advanced Series pumps possess the versatility that allows them to be used at every stage of the paint-and-coatings production process, from raw-ingredient transfer to mixing, batching and lling.
Wilden Pump & Engineering Company

www.wildenpump.com
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Pumps & Seals

O-Ring Calculator App
Trelleborg Sealing Solutions (TREL-B) has announced the release of the O-Ring Calculator app. The new app calculates O-Ring dimensions and tolerances and recommends sizes and Trelleborg Sealing Solutions part numbers. This new app joins the successful ISO Fits & Tolerances and Unit and Hardness Converter. All are available in English or German, free from iTunes or via the Apple App Store on the iPhone and iPod Touch.
Trelleborg Sealing Solutions

www.tss.trelleborg.com
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Pump for Lime Slurry Applications

The Bredel SPX reliably handles a variety of harsh materials, such as abrasive lime slurries. Advanced peristaltic technology enables the SPX to pump abrasive and corrosive chemicals dependably for a long period of time. The precision-machined hose is designed for long-life even when pumping slurries that cause other pumps to fail. With ow-rates up to 350 GPM and pressures up to 232 PSI the Bredel SPX hose pump is designed for continuous duty under the most difcult application conditions.
Watson-Marlow Pumps Group

www.wmpg.com
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Chemical Dry Vacuum Pumps

Edwards has launched a new range of dry pumps that delivers exceptional vacuum performance in harsh chemical, petrochemical and pharmaceutical processes. The easy-to-use CXS pumps feature cutting-edge tapered-screw technology; have excellent reliability; are simple to install; environmentallyfriendly; and give improved liquid and solids handling, according to the manufacturer. As a result, they are economic to run and users can optimize their vacuum processes and minimize overall cost of ownership.
Edwards
www.edwardsvacuum.com
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18
Pumps & Seals

Effective Communication in the Pump Business
Ross Mackay
Ross Mackay Associates Ltd.
I know you believe you understand what you think I said, but I am not sure you realize that what you heard is not what I meant. The main problem arises if you can make any sense at all of the opening sentence, but it exemplies the most prevalent problem in the pump business today: effective communication. It nally happened! I could see it coming from the increasing dependency on buzz words, acronyms and letter abbreviations by so many who make presentations in our industry. I attended a workshop where I hardly understood a word that was being said. OK, maybe Im exaggerating a bit. After all, I knew the speaker was discussing how to improve system reliability, but I really did not understand the key points that were being made. On too many occasions during the presentation, I found myself on the receiving end of a barrage of words that were not even English. All the keywords were in Greek. The speaker actually was using the Greek language for terminology that could just as easily have been dened in English. The classic phrase was: If we increase the Beta, then the Omega will be improved at the same time. This statement was made with no subsequent explanation of either Beta or Omega.
Lets get serious! The English language has enough confusion built in lets not add to it. Effective communication is essential to good business, so why do we need to introduce a second language? Its worth remembering that the rst rule of communication is that it is the speakers responsibility to ensure that the message he or she is attempting to deliver is received as it was meant to be received. The onus of understanding is not on the recipient. In other words, if there is something in this article you dont understand, then the fault is mine not yours. Most people would consider the number one problem of communication to be that it does not happen. Such is not the case. Try as we might, instead of improving communication, contemporary society still seems compelled to make it more difcult. The use of buzz words, acronyms and other letter abbreviations is increasing at a dramatic pace. We in the pump business have long been familiar with the terms BEP and TDH. Some years ago, we started discussing MTBF, until someone decided they didnt like the implication and changed it to MTBR. Is there really a difference between the Mean Time Between Failure and the Mean Time Between Repair? Besides, its been almost 20 years since the initial concept was discussed, and we are still arguing about what it means and how to measure it. These were the same problems we had before the term(s) was introduced.
Frequently, the creation of a new series of acronyms or other letter-type abbreviations is simply an attempt to make a concept appear substantially different from previously known data, when in fact, its the same old stuff with a different name. The only reason for it to be given a different name is so that the individual who thought it up might be considered unique. For example, I recently read about LOD and ROD in a discussion of a pump curve. As it turns out, the author was simply referring to the position of the actual operating point as being to the Left or Right of the Design Point. He could have said so quite plainly without resorting to the undened acronyms. So, if we implement Lean Six Sigma to achieve the lowest MTBF, we may have to get the IT people to utilize an EAM/CMMS with RCM and hire a CMRP to introduce PM procedures ASAP! Better yet, why dont we just do whats required to stop the frequent and repetitive pump failure? Then, lets do lunch at KFC. And people ask me why I also teach Presentation Skills! Ross Mackay specializes in helping companies increase their pump reliability and reduce operating and maintenance costs through pump training programs. Working out of Aurora, Ontario, he is the author of The Practical Pumping Handbook and can be reached at 1-800-465-6260 or through his website, www.practicalpumping.com.
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Sustainable Food Packaging Solutions

Turnkey Automated Batching System Helps Company Reach Sustainability Goals
Biosphere Industries was founded in 2002. Its mission, according to founder Elie Helou Jr., is reected in its name. Biosphere sought to provide closed-loop food packaging systems that have minimal to no impact on the earths natural life cycles, he explains. Using yearly renewable raw materials, and ultra-efcient (essentially no-waste) manufacturing processes, we wanted to deliver truly earth-friendly solutions. Helou is an aeronautical engineer and a recognized expert in composites technology. A major priority was using yearly grown raw materials that would have minimal impact on the environment. Other priorities related to dening the material. We wanted to create a material that was primarily starch-based, he explains. Tapioca was chosen due to it allergen-free nature some people are allergic to other starches, such as potato. We wanted it to be harvestable without killing the plant, so the supply would be annually renewable. We wanted it to be rigid, too and have insulating properties so it could be a replacement for EPS or Styrofoam. Five years into the development effort, Biosphere introduced an entirely new technology, in terms of both its composition and its process, for sustainable single-use food packaging that met all of these requirements and more. Now marketed under the trade names Biosphere Bakeware and Blueware Serveware, it is unique in its approach: Rather than convert starch into plastic, the Biosphere process bakes the starch in a process similar to the baking of bread or mufns (ironically, two of the product categories that benet most from the technology more on that later.) Ingredients in Biospheres unique platform technology include tapioca starch as the primary ingredient and a lesser amount of grass bers and additives custom to each recipe that add strength, exibility or color. The most critical aspect of the manufacturing process is ingredient batching, which must be highly accurate. The accuracy requirement was the spec most off-putting for vendors when we looked for a system, offers Helou. Our goal was to combine high output, which we expected to accelerate over time, with ingredient accuracy that would never deviate more than 0.5 percent.
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Food Equipment
Helou and his engineering team interviewed several candidate vendors and, on the basis of speed, repeatability, lead time for completion and cost, selected a turnkey automated batching system engineered and manufactured by Ingredient Masters Inc. of Cincinnati, Ohio.
The Equipment The rst of the ve modules is a super sack bulk handling system comprised of six 54 cu. ft. dispensing hoppers arranged in a single row. Each is equipped with pneumatic slide gate valves with dual dribble positions to optimize cycle times and discharge accuracy. Air-activated vibration at each hopper is controlled by a PLC to ensure consistent product ow. A robotic scale cart, also governed by the PLC, moves under the dispensing hoppers and receives the precise amount of each ingredient specied in the recipe. The scale cart automatically docks with a transfer hopper to transport the ingredients. There are computer-controlled dust collection points at each of the ve hopper
discharge sites; dust collection can also be activated manually during hopper relling. The second module, a vacuum transfer system, is controlled by the central computer system. It automatically requests delivery of the next sequence of material whenever a premix hopper is empty. It has a primary premix hopper mounted over the mixer that discharges through the mixer port, and a secondary premix hopper that discharges into the primary. A vacuum receiver mounted above the secondary hopper transports ingredients sequentially from the scale cart transfer hopper into the secondary premix hopper. Module 3 is a ber handling system with a mechanically agitated hopper mounted on load cells. It functions as a loss in weight scale hopper and can also be lled from an existing ber shredder discharge conveyor. System control is provided by an Allen Bradley Compact Logix PLC running RSLogic 5000 for the PLC logic and RS view for operator graphics. A Dell Pentium computer runs Windows XP and RSLix provides PC to PC communication. A Microsoft access database stores recipe and ingredient information and records batch data.
The Process Powdered raw material (there is also a liquid component) for both Biosphere product lines is received in 650 kg to 1000 kg super sacks, and subjected to full lab inspection using commercial bakery standards. Super sacks are installed on racks using a fork lift and frame, and contents are released into hoppers. When an order is received, the operator creates a job order containing the recipe information, number of
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Food Equipment
batches to be run, and batch size. The computer conrms the availability of each dry ingredient and sends the job order information to the PLC. While the previous batch is mixing, the operator places a mixer bowl under the discharge of the rst (ber) hopper and initiates batching. When all starting conditions (equipment positions, material availability) are met, a robotic cart moves to the station containing the ller and receives the discharge specied in the recipe. Ingredients are metered to a gain-in-weight type weigh scale the type most often used in food and pharma processing due to its higher accuracy and more manageable sanitation routine. When discharge is complete, the scale cart docks with the transfer hopper and sends the ller to the receiving hopper above the mixer, then through the secondary premix hopper, to the primary. The PLC then discharges the ller and meters liquid #1 into the mixer. Following ber transfer, the cart moves to the starch hopper, then on to the remaining ingredients some of which are as ne as powdered sugar with scent and colorant (if specied) as the nal additions. When each batch is complete, the system displays the recipe amount for each ingredient, along with actual amount discharged. The system is distinctive in that it supplies all of the required material to the mixer without delaying the mixing cycle. The Ingredient Masters system maintains a deductive inventory of the material in each dispensing hopper. When a discharge is made, the PLC deducts the amount from the available weight in the hopper. When a hopper is relled, the operator enters the weight of the bulk bag into the computer and the PLC adds the weight to the available weight for the hopper. The discharge accuracy of the system for a 540-lb. batch is shown on the chart. The Ingredient Masters system can produce one batch every seven minutes. Biospheres material has proven ideal as bakeware. Mufn trays and pie pans are excellent applications, as are bakeware products with unique features, or deep draw requirements the material will produce product with depths of 9-inches and greater. The material has exceptional insulative properties, and adequate short-term moisture-resistant properties as well, so its a natural for ice cream. Bakeware is where we started selling the technology, says Helou, because the material lets companies bake and sell in the same pan. The insulating properties are of great interest to the cold markets, such as smoothie and yogurt stores. The yearly grown 100 percent nonpetroleum-based formula developed by Biosphere has proved well-suited to high volume production. At its Carpentaria, Calif.-development center, Biosphere has been able to test and fully develop this new technology. The company is evaluating sites for a second production facility in the Midwest. Our goal, says Helou, is to source locally and use locally. We want to put farmers to work here, growing starch, bamboo and other ingredients, and avoid importing anything from abroad.
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Ingredient Masters
www.ingredientmasters.com
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BetterSafe
Than Sorry!
Based on the harmless appearance of a bagel, its hard to imagine that making these popular treats may, in fact, pose an occasional hazard. But its true, according to ofcials at a Canadian bread manufacturing company based in Toronto, Ontario. Used extensively in the bagel making process, highly pressurized hot water required during boiling offsets potential quality problems. The process also requires a ltration system to clean raisins, sesame seeds, bits of dough, corn meal and other materials out of the hot water. And thats where the danger can occur. The company was using duplex bag lters for several years and was concerned about employee safety because of the hazards of manually changing lter bags while working with the high water temperatures.
Self-Cleaning Water Filters Help Bagel Maker Improve Safety
Challenges The bread company planned to install a new bagel boiler in its Alberta, Canada, plant, which required a ltering system. Corn meal can create water quality problems if the temperature falls, requiring an expensive and timeconsuming water change. It is critical that the water in a bagel boiler remain at a high temperature, even as it is ltered and recycled. With employee safety in mind, the maintenance supervisor at the companys Alberta plant wanted a ltering system that required less operator intervention than a bag system. High water temperatures used in the process can be a serious hazard to an operator changing lter bags, especially when pressed for time during the shutdown process when an operator may open up the lter housing while it is still pressurized. Solution Decision-makers at the Alberta plant wanted a lter they could count on,
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without the hazards occasionally associated with bag lter maintenance. Working with Eaton, the plant manager and maintenance supervisor determined that the Eaton DCF mechanically-cleaned lter was the permanent solution to meet their business objectives. The plant installed two Eaton DCF-800 lters on the boiler water recycle line at the Alberta facility. DCF lters successfully removed the raisins, sesame seeds, bits of dough and corn meal that would adversely affect the nal product. Uninterrupted ltering by the DCF also ensured consistently high water temperatures required to maintain boiler water quality. The DCF performs a self-cleaning action by mechanically scraping collected debris from the lter screen with a disc that travels up and down the screen, parallel to the liquid ow. The collection chamber at the bottom of the lter automatically purges collected debris without halting production, in a process that takes less than seven-tenths of a second. Because the DCF continuously cleans the screen without interrupting production, it maintains a consistently high ow rate and provides the highest quality ltering. In fact, the company was so happy with the performance of the DCF lters at its Alberta plant, the Langley, British Columbia facility also installed DCF lters on its bagel boiler systems instead of previously planned bags.
Eaton Corporation
www.eaton.com
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Results The Alberta facility has eliminated the risk of operator injury related to changing lter bags because there are no bags to remove and media cleaning is automatic. The facilitys supervisors were also impressed with the unsurpassed ltering of its bagel boiler water and the ability to a maintain high water temperature while avoiding water quality problems. Meanwhile, the plant is realizing nancial and environmental gains by eliminating media, reducing worker exposure and reducing labor and disposal costs.
Water/Waste Processing, a supplement to Processing magazine, helps connect you to the booming global water and wastewater market. And dont miss WaterWaste.com, Processings new website dedicated to water/wastewater treatment.
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Food Equipment
Spear Tip Piercing pH Electrode
Food industry process and plant engineers in need of a durable, highly reliable penetration pH sensor for applications requiring sample piercing will nd that the S175CD Spear Tip Piercing pH Electrode from Sensorex is ideal for measuring the pH of semi-solid material samples such as meat, sausage and cheese. The S175CDs pH electrode features an extremely rugged glass measuring spear-shaped tip, which is enclosed in a durable, virtually unbreakable epoxy body. Its gel-lled, double-junction reference design provides protection from contaminating samples and provides extended service life if used with samples that interact with silver ions. An extended surface area semi-porous PVDF (Kynar) thermoplastic provides the junction with excellent sample contact.
Sensorex
www.sensorex.com
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Metal Detectable Fluidizer Disk

In response to requests from food manufacturers who are looking for the highest purity for their product, Solimar Pneumatics has developed a metal detectable uidizer disk. Solimars uidizer disk mounts on the storage vessel wall and utilizes air pressure to unload powder and bulk solids faster and completely without bridging and rat holing. The proven system is used for silos, hoppers and dry bulk trailers. Solimars silicone aerators have the highest manufacturing quality control and an excellent record of structural integrity, according to the manufacturer.
Solimar Pneumatics
www.solimarpneumatics.com
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Forming Machine
Speed, product consistency and versatility are key to NuTEC Manufacturings 710 Forming Machine. The 710 provides excellent weight control and gentle product handling for a variety of products from beef to vegetables, according to the manufacturer. It can form hamburger patties, meatballs, skinless sausage links and many more items. The 710 Forming Machine operates with minimal wear and maintenance. NuTEC supports the machine with factory direct service and a one year parts warranty. Like all NuTEC equipment the 710 is operator-friendly and easy to use.
NuTEC Manufacturing
www.nutecmfg.com
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Plant Automation
Free Literature for Automation
Free literature from Omega Engineering contains over 100 full color pages of the latest state-of-the art products from Omegas automation line: programmable logic controllers, smart relays, enclosures, process measurement and control devices, motion control sensors, human machine interface, pushbuttons, proximity sensors, relays and timers, wire connection and more. A user-friendly index is available for easy product search, economical choices, popular models and accessories.
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Omega Engineering
www.omega.com
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Flowmeters for Chilled Water and Steam Flow Measurement

Engineers and facility operators who need to measure steam or chilled water for either district energy, power plants and/or facility HVAC control systems will nd McCrometers FPI Mag (Full Prole Insertion) and V-Cone Flowmeters provide superior performance with installation exibility and low maintenance at economical life-cycle costs, according to the manufacturer. The hot tappable FPI Mag Flowmeter is ideal for measuring chilled water in large campus evaporative HVAC systems. The advanced V-Cone Flowmeter delivers precision steam measurement in a space-saving design.
McCrometer
www.mccrometer.com
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Automated Boiler Blowdown Control System The automated Model 61 Boiler Blowdown Control System from Electro-Chemical Devices offers a complete system providing continuous control of the surface blowdown rate for commercial and industrial boilers, optimizing blowdown cycles and reducing scaling and corrosion, according to the manufacturer. With its precision accuracy, the automated Model 61 Boiler Blowdown Control System reduces boiler maintenance make-up water consumption and the energy needed to heat it. In comparison to performing blowdown cycles manually, the system offers operational cost advantages by continuously adjusting the blowdown rate to optimize the boiler waters electrolytic conductivity. Electro-Chemical Devices
www.ecdi.com
Getting Serious
About Lubrication
Why Many Lubrication Tracking Methods Fall Short
Industrial facilities often believe they have equipment lubrication covered with existing tools and systems from spreadsheets to condition analysis to sophisticated preventive maintenance (PM) and corrective maintenance (CM) programs. However, despite millions of dollars spent to improve machine condition and reliability, improper lubrication is still cited as the primary cause of premature equipment failure today. Lubrication is the neglected stepchild of equipment reliability and doesnt get the attention it deserves, says James Wanstreet, the reliability engineer and Lubrication Department supervisor at KapStone Paper and Packaging Corporations Charleston Kraft paper mill in Charleston, S.C. As the limits of existing lubrication tracking methods become more apparent, separating lubrication from traditional PM and CM efforts to focus on lubrication reliability is increasingly being adopted as a solution. While lube tasks are considered routine and often assigned to the newest techs at the plant, it is critical to get the right lubricant in the right place at the right time using the right procedure or technique. Yet it is far too easy to miss lube points, mix up lubricants or over/ under lubricate when relying on traditional lubrication tracking methods.
Traditional Lubrication Methods

At its most basic, plants rely on a technician armed with a grease gun and human memory to track lube points. Although these technicians do a stellar job with the tools they are given, human memory is fallible and mistakes can be made and lube points missed. Even the smartest, most meticulous technician can forget things from day to day, says Wanstreet. Another solution used in many plants is the ubiquitous spreadsheet. Spreadsheets can be used to store or change information, but are inherently static and offer no real lubrication point tracking or history. For example, spreadsheets do not calculate and schedule future lubrication tasks based on completing a current task. And if a lubrication task is missed, theres no record of it. Although early detection tools are used to identify and address a problem before it worsens, this approach is really more reactive than proactive. After all, if lubrication is poorly managed, early detection tools are going to repeatedly indicate a problem. Proper lubrication, on the other hand, can prevent damage or excess wear before it starts. Although CMMS systems work very well for managing PM and corrective work at the equipment level, they are not built for detailed tracking of individual lube tasks, particularly at high volume. Even so,
Lubrication Tracking Methods Fall Short

Performing lubrication seems elementary and has been approached the same way for many decades. However, it is much more complex than it is given credit for. With almost 500,000 lube tasks a year in our plant on almost 8,000 pieces of equipment, its critical that the correct lubrication get done without fail, says Wanstreet. Lubrication is the life blood of plant equipment and foundational to keeping it working correctly.
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CMMS systems are often utilized for this very purpose and this is where the difculty begins. To compensate for a lack of lubrication focus and detail, CMMS systems rely on a series of lubrication PMs, arranged according to lubricant type, frequency and plant location. However, it can be time consuming to sort through multiple PMs to view lubrication requirements for a specic piece of equipment. Furthermore, if a change is required to the type of lubricant, which is typically stored in a text eld, or frequency, each applicable PM must be found and each detailed line item requiring a change corrected. when needed based on its frequency. Since weve been using LUBE-IT, were staying on top of lubrication tasks without forgetting any, concludes Wanstreet. I estimate were getting about 25 percent more equipment uptime with fewer staff, with ROI in about one year.
Generation Systems Inc.

www.generationsystems.com
Write In 524
A New Focus on Lubrication Reliability

Whats needed is an approach dedicated to lubrication because hundreds of thousands of annual lubrication tasks are virtually impossible to adequately manage through human memory, a spreadsheet, early detection tools or buried in lists of PM work orders. Fortunately, dedicated lubrication software is now transforming industrial lubrication management from an error-prone manual chore or inadequate CMMS effort into a predictable, automated process. For instance, LUBE-IT by Generation Systems, an Issaquah, Wash.-based developer of lubrication-specic tracking and management software, offers task specic scheduling and tracking management to ensure that the right lubricant gets to the right place at the right time in the right amount, using the right procedure or technique, all the time. Each lube point and related tasks are inventoried including location, capacity, activity type, procedure, frequency, route and shutdown requirements. From that, the software manages all these lube tasks automatically and simplies changes to any of the variables as needed. Once it has all the lube points, the software will reschedule a task based on when it was completed. In this way, the software takes responsibility for hundreds of thousands of lubrication tasks annually, essentially ensuring that none are left behind as a result of the tracking/organizational system itself. KapStone Paper and Packaging Corporations Charleston Kraft paper mill turned to Generation Systems dedicated lubrication management software. With the software, reliability engineers and plant managers can quickly view the details and history of any lubrication point, including notications of any equipment issues identied during the lubrication activity. Details for each lube task are available via paper-based lists or rugged mobile computing devices so lubrication tasks that need to be completed are clear and known each week. Since the software dynamically releases that work for individual tasks, the lube tasks will only appear
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Plant Maintenance & Safety

Industrial Sounder
The new PATROL Model PA 1 from Pfannenberg is a new generation, 100 db industrial sounder. By electronically generating acoustic tones (no moving parts), reliability is one of the greatest benets, according to the manufacturer. Mechanically, the housing is manufactured from a blend of polycarbonate and ABS for durability.
Pfannenberg Inc.
www.pfannenbergusa.com
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Instrument Power Supply

The Instrument Power Supply with battery power provides uninterrupted 24VDC for standard monitoring equipment. The three-stage battery charger, powered by 115/230 VAC at 50 to 60 hertz maintains the 12 VDC battery at peak performance levels. The power system is designed to maintain a full charge that will provide 24VDC output during a loss of AC power for up to three days, according to the manufacturer. Membrane panel status lights provide diagnostic information for various system congurations. Optional RS232 serial port and relay interface module relays provide a variety of output information possibilities.
Halogen Valve Systems Inc.

www.halogenvalve.com
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The Importance of
Thorough Mixing
Glass Blended Rapidly with Abrasion-Resistant Rotary Mixer
While most reading this article may be unfamiliar with the Kopp Glass name, most are likely familiar with Kopp Glass products. From a humble beginning more than 80 years ago as a manufacturer of red glass for railroad signals, Kopp now claims to be the worlds leading producer of precision molded industrial quality technical glass. The company is known worldwide among the industries it serves as a producer of molded borosilicate glass, a tough material that can withstand harsh industrial environments and is resistant to degradation from sunlight and weathering. The company offers more than 300 standard glass compositions, plus custom formulations, in any desired shade of color. The glass is used worldwide in such diverse applications as airport and aircraft lighting, chemical process equipment, medical device illumination, light lters of all types (including military night vision equipment), electrical transformers, architectural and theatrical lighting and railroad and trafc signals. Kopp glass can even be found at the South Pole, where scientists have installed a computerized network of thousands of 14-inch-diameter (35.5 cm) glass globes about a mile below the surface of the ice. The globes contain sensors, with the goal of capturing sub-atomic particles, called neutrinos. Kopp produces its glass in small batches, typically in the range of 100 to 1,000 pieces, says David Pungratz, the The lange of a discharge valve at the hoppers outlet is positioned atop the inlet of the mixer using an overhead hoist and trolley, companys mix and melt manager. The
due to ceiling height restrictions.
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powdered ingredients are mixed, melted in a pot furnace, then molded by skilled craftsmen. All our products are made by hand, he says. operator manually shuts off the conveyor. Other major ingredients are added manually, one by one. Finally, the minor ingredients, which are pre-weighed, are introduced into the batch. When the batch is complete, the hopper is raised into position above the mixers inlet by an overhead hoist and trolley. The ange of a discharge valve at the bottom of the hopper rests on a rubber seal afxed to the mixers inlet, after which the valve is opened and material ows into the machine, aided by two vibrators located on the exterior of the hopper.
The Importance of Thorough Mixing

The mixer is a vital part of Kopps operation. A batch may contain anywhere from ve to 15 ingredients that must be mixed thoroughly in order to guarantee product quality, says Pungratz. Kopp uses a rotary mixer made by Munson Machinery Co., Inc. of Utica, N.Y. It replaced a rotary pan mixer that had been in the plant for many years. The rotary mixer is a horizontal, rotating drum that is supported on either end by trunnion rings and driven by rollers, powered by a 5 hp (3.7 kW) motor. It has a stationary inlet at one end and a stationary outlet, with a discharge gate, at the other end. Mixing ights or bafes tumble the batch in a multi-directional manner.
Access doors facilitate interior inspection, cleaning and maintenance.
While many ingredients are used in Kopps products, sand accounts for 60 to 75 percent of a formulation, so sand is delivered to a silo in tanker trucks of 40,000 lb (18,144 kg) capacity. The rest of the ingredients, including borax, metal oxides and various other minerals, arrive in bags, drums or barrels. The ingredients for a batch are loaded into a large rectangular hopper that is set on load cells. Sand from the silo is fed to the hopper by means of a screw conveyor and a chute. When the amount of sand reaches the preset weight, an
The batch is rapidly discharged from the mixer into a cart that transports it to the furnace.
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Powder & Bulk Solids

Mixing is Rapid
The mixer (model GB10 glass batcher) has a capacity of 10 cu ft (2.8 cu m), or 1,500 lb (680 kg) for glass. However, Kopps operation is limited to 700 lb (317 kg) by the size of the hopper. Pungratz explains that larger hoppers cannot be used because of the limited clearance above the mixer. The liner and other contact surfaces in the glass batcher are made of abrasion resistant steel, designed to withstand the abrasive mixture of ingredients, particularly sand, in Kopps formulations. Mixing times are
We just have to grease a couple of fittings about every two weeks, and in the six years weve owned the machine we have not seen any wear on the liner and have had to replace only one seal.
only about ve minutes less than half the time required by the pan mixer, says Pungratz. Nevertheless, the machines slow tumbling action, aided by the bafes, makes for a homogeneous mix. We make the best hand-pressed glass in the world, with minimal defects, he asserts, so our standards are very high.
SIFT, CLASSIFY, DEWATER & DEDUST

dry bulk and slurries in 1 to 5 fractionsfrom several pounds/ kilograms to 70+ tons/hwith VIBROSCREEN circular vibratory screeners.
SCALP, DEWATER AND DE-LUMP

dry bulk materials and solids-laden slurriesat rates from several pounds/kilograms to 70+ tons/h with Quick-Clean CENTRI-SIFTER centrifugal screeners.
Kopp replaced a rotary pan mixer with a Munson rotary batch mixer a horizontal, rotating drum with a stationary inlet at one end and a stationary outlet at the other. Mixing lights, or bafles, tumble the batch in a multi-directional manner.
COOL OR MOISTURIZE
bulk materials at lab to production rates using minimal energywith ultra-ecient, self-contained, Quick-Clean, Circular Fluid Bed Processing Systems.
See hundreds of models in gravity-fed, in-line-pneumatic and quick-clean designs to food, dairy, pharma and industrial standards at kason.com USA CAN UK +1 973 467 8140 +1 514 667 6777 +44 (0)1782 597540
Once a batch has been mixed it is discharged into a wheeled cart or wagon and taken to a furnace. Kopp has two furnaces, one of which can accommodate 16 melting pots and the other 12 pots. Most of the pots have a glass capacity of 2,500 lb (1,134 kg). The furnace operates at 2,600 F (1,427 C), but the temperature of each pot can be individually controlled and ranges from 2,0002,500 F (1,0931,370 C), depending on the composition of the glass.
A Matter of Individual Skill

When a batch of glass is ready for use the pot is opened and cooled to a working temperature, then the glass is cast in molds of stainless steel or cast iron. This operation is carried out by two skilled craftsmen, whose respective job titles are glass gatherer and presser. Each piece is made individually.
AA-0335
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The gatherer accumulates the appropriate amount of glass needed for the piece, using a punty a steel rod that has a clay ball on one end. The punty is placed into the mouth of the pot until it touches the molten glass, then the punty is turned in a way that gathers glass on the clay ball. The glass is carried to and released into the mold and the presser shears off the ow, then pulls a lever to bring the plunger (the molds male part) into the mold. Pungratz notes that the glass gatherer and the presser use their experience to calculate the exact amount of glass needed for a piece. Large products, such as 24 inch-diameter (61 cm dia) Fresnel lenses, are made by layering three molten gobs of glass. Meanwhile, the mixer provides a continual supply of mixed glass ingredients to the furnaces. As soon as one batch has been discharged, the machine is cleaned and readied for the next batch. The machine processes 10 to 20 batches per day, typically of several different colors, so it is important to avoid residue from one batch that might contaminate the next one. However, contamination has not been a problem with the glass batcher, says Pungratz. Essentially all the material is rapidly discharged, leaving minimal residue, he says, and cleaning takes only about 10 minutes, using a dedicated vacuum. A door on the side of the machine provides full access to the interior. A second vacuum system removes any airborne dust that results from the cleaning operation. However, in contrast with the pan mixer, the rotary mixer generates very little dust, says Pungratz, and this was a big selling factor for us. He adds that the rotary machine is extremely quiet, while the pan mixer was very noisy. Another big advantage is that the mixer is essentially maintenance-free, he says. We just have to grease a couple of ttings about every two weeks, and in the six years weve owned the machine we have not seen any wear on the liner and have had to replace only one seal.
Munson Machinery Co., Inc.

www.munsonmachinery.com
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Bulk Bag Conditioner
The new BLOCK-BUSTER Bulk Bag Conditioner from Flexicon Corporation is equipped with two hydraulic rams and specially contoured end plates. The conditioner presses opposing sides of bulk bags, loosening material that has solidied during storage and shipment, enabling bulk bag unloaders to discharge through bag spouts. A cantilevered I-beam with motorized hoist and trolley allows loading and unloading of bulk bags without the use of a forklift.
Flexicon Corporation
www.exicon.com
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Dust-Tight Drum Discharging System

MTS hydraulic Lift & Seal System seals drum to a dust-tight pour cone with outlet valve for a clean, contaminant-free product transfer. Patented Control Link Rotation System provides 180-degree drum rotation for maximum product discharge. Interior of pour cone features uidizing pads and a material agitator. Units are available with discharge heights up to 40 feet, rotation to 180 degrees, for any size drum or container. Systems are custom designed to meet your application requirements.
Material Transfer & Storage

www.materialtransfer.com
Write In 530
Sanitary Pin Mill

A new 34-inch sanitary stainless steel Pin Mill model CIM-34-SS from Munson Machinery provides coarse to ne grinding of friable powders, akes and granules into controlled particle sizes. High-speed rotation of the inner disc creates centrifugal force that accelerates bulk material entering the central inlet of the opposing stationary disc. As material travels from the center to the periphery of the discs at high speed, it passes through a path of ve intermeshing rows of rotating and stationary pins, with the desired tight particle size distribution obtained by controlling the rotor speed.
Munson Machinery
www.munsonmachinery.com
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Modular Sifter
The Modular Tru-Balance sifter from Great Western Manufacturing is a simple and economical machine with reliable performance and excellent sanitation features, which are ideal when requirements do not dictate stainless steel construction or complex separations. The Modular Tru-Balance Sifter utilizes four to nine sieves and can obtain up to three separations. Numerous construction options means the Tru-Balance Modular sifter can be adapted to a wide range of products.
Great Western Manufacturing

www.gwmfg.com
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Sieve Tower Analyzer

HK Laboratory/Pilot Sieve Towers from Cleveland Vibrator Company have a unique, heavy-duty, vibratory design that enables quick sieve analysis of product samples with maximum throughput. With a choice of an optional electromagnetic jogger table, or standard dual outboard rotary electric drives, users are equipped with variable speed settings that permit complete control. Units are available in 8-, 12- or 17-inch diameter sieve sizes down to 635 mesh. Additional features include electric or air operation for tabletop or caster use and quick clean-up.
Cleveland Vibrator Company

www.clevelandvibrator.com
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Two-Deck Sanitary Classier A new Vibroscreen Two-Deck Sanitary Classier from Kason Corp. separates up to six tons per hour of bulk solid material into three fractions, according to the manufacturer. Measuring 30 inches in diameter, it classies materials ranging from dry bulk solids to solids-laden slurries. It is constructed of stainless steel with ground and polished welds, and equipped with sanitary epoxy-mounted screens. Quickdisconnect clamps between each screen frame provide rapid interior access for inspection, screen changes and wash down. Kason Corporation
www.kason.com
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Tanks & Vessels

Corrosion- and Chemical-Resistant Polyethylene Tanks
Assmann Corporation has a full line of corrosion- and chemical-resistant tanks and containers. Constructed from virgin high-density crosslink or FDA-compliant linear polyethylene, the tanks and containers are used to store and transport corrosive and hazardous materials. They provide low-temperature impact resistance, are UV stabilized and come in wide range of capacities and colors. Custom rotational molding, accessory ttings and custom colors are available.
Assmann Corporation of America

www.assmann-usa.com
Write In 535
Liquid and Dry Bulk Storage Systems

CST Storage and CST Covers offer exible and integrated liquid and dry bulk storage system design options for applications worldwide. CST Storage (formerly Columbian TecTank and Engineered Storage Products) is a provider of modular, factory coated steel storage tanks and covers, offering glass-fused-tosteel (Aquastore) and epoxy coated (BulkTec and HydroTec) tanks appropriate for nearly all liquid and dry bulk storage applications. CST Covers deliver engineered cover solutions in aluminum domes, at panel covers and custom structures appropriate for CST Storage tanks as well as new and pre-existing concrete and steel tanks.
CST Industries
www.cstindustries.com
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Compare which Tanks & Vessels are best for your application at
ProcessFlowDirect.com.
ProcessFlowDirect
Info Center
Largest Vibratory Classifer Separates Up to 70 Tons/h
Vibroscreen High Capacity, Two-Deck Classier separates up to 70 tons/h of bulk chemicals, minerals, plastics, foods, pharmaceuticals and other materials into three fractions. Operates on a batch or continuous basis.
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Stainless Steel Tube Fittings

20-page catalog from CPV Manufacturing describes Mark VIII O-SEAL stainless steel tube ttings that will not shake loose. Unique leakproof sealing system allows easy slip-in, slipout connections matched to your system.
Prevent Chemical Spills with Double Wall Tanks

Cylindrical double wall tanks from Assmann Corporation provide the best protection against hazardous chemical spills. Assmanns molding process provides a heavier-top sidewall and dome to prevent dome collapse.
Kason Corporation
info@kason.comwww.kason.com 973-467-8140
CPV Manufacturing, Inc.

851 Preston St. Philadelphia, PA 19104 215-386-6508Fax215-387-9043 www.cpvmfg.com Write In 400 Write In 401
Assmann Corporation of America

www.assmann-usa.com/Double_Wall_Tanks.htm
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Hannay Reels SS3000 Series for Sensitive and Harsh Environments

Hannay Reels SS3000 Series of stainless steel reels provides superior protection against corrosion. Paint-free surface eliminates the potential for rusting associated with chipping.
Efcient Plastic Diaphragm Valve Solution

The new R677 and R690 Diaphragm valves from GEMU have been designed to be a highly efcient plastic diaphragm valve solution. The optimized internal geometry provides higher Cvs and improved ow characteristics.
Fast Homogeneous Mixing
TheBellaFluidizedZoneMixer by Dynamic Air achieves fast, high-capacity, low shear, precisionmixingofeitherdrybulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixedwithafast,eficientand gentle action.
Hannay Reels
catalogs@hannay.comwww.hannay.com
Gem Valves
www.gemu.com
Dynamic Air Inc.

St. Paul, MN 651-484-2900 info@dynamicair.comwww.dynamicair.com Write In 404 Write In 405
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Packaging Protection for any Product

Plastic netting from Caplugs is used as packaging protection for just about any product. The netting is available in at sheets for layering or in sleeves to slip over an object. The netting cushions your product during shipment, which keeps it free of damage.
Pressure Measurement for Process Industries

Keller manufactures pressure measurement instruments utilizing state-of-the-art electronics and proven piezoresistive technology to provide outstanding accuracy, longevity and price. For more information, please call us or visit our website.
NEW Brochure!
VAC-U-MAX, a custom builder of pneumatic conveying systems for bulk powders, introduces a NEW brochure detailing the capabilities and 50+ years in the bulk dry powder industry.
Caplugs
1-888-CAPLUGS www.caplugs.com
Keller America, Inc.

877-253-5537 www.kelleramerica.com Email: sales@kelleramerica.com Write In 406 Write In 407
VAC-U-MAX
800-VAC-U-MAXwww.vac-u-max.com Email:info@vac-u-max.com
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High Accuracy Digital Pressure Gauges

Omegas new DPG409 series of high accuracy digital pressure gauges feature a large backlit display makes it possible for user to read digits from over 10.7m (35 ft). The rugged Stainless Steel enclosure is designed specically for wash-down, sanitary and marine applications.
Model 60B Flow Computer

The 60B Flow Computer constantly processes pressure, temperature and ow data from a Laminar Flow Element (LFE) with a resulting accurate (.75 percent of point-NIST traceable) display of Standard (Mass) and Volumetric ow. Totalizers and optional outputs are available.
Model 3012 DSP Screw Press

The Screw Press is the ideal choice for the small WWTP plant with a low washwater requirement. An independent prethickening rotary drum thickener enhances capacity and cake solids. In-house fabricated slotted screen allowsformaximumdrainageand avoids plugging or blinding.
OMEGA ENGINEERING, INC

One Omega Drive, Stamford, CT 06907 203-359-1660 Fax: 203-359-7700 www.omega.com Write In 409
CME, Div. of Aerospace Control Products

1314 West 76th Street, Davenport, IA 52806 www.cmelow.comE-mail:info@cmelow.com 800-845-0927 Write In 410
BDP Industries
www.BDPIndustries.com
Write In 411
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Info Center
Krytox Fluorinated Lubricants
Krytox Greases and Oils are: chemically-inert; nonammable; thermally stable, -103 to 800 F; oxygen-compatible; no migration; low outgassing. Krytox offers extreme pressure, anticorrosion and anti-wear properties. Mil-spec, aerospace and food grades!
Loss-in-Weight Feeders
The MECHATRON Lossin-Weight Feeders provide processing industries precise material feeding accuracies of 1/4 to 1 percent of feed rate setpoint at 2 sigma. Complete disassembly from the non-process side of the feeder. Feed rates from .002 to 1,100 ft per hour are achievable.
High Performance Mixers

PHLAUER High Performance Mixers are solving customers mixing problems by providing repeatable, predictable, reliable performance. Accurate mixing to 0.5 percent standard deviation and Cv of 5 percent in small samples. Single and double rotor machines with shear available on demand.
Miller-Stephenson Chemical Co., Inc.

California - Illinois - Connecticut - Canada www.miller-stephenson.com Email: support@miller-stephenson.com 203-743-4447 Write In 412
Schenck AccuRate
746E.MilwaukeeStreet,Whitewater,WI53190 800-558-0184 www.accuratefeeders.com/mechatronfeeders.html Email: mktg@accuratefeeders.com Write In 413
A&J Mixing International Inc.

8-2345 Wyecroft Road, Oakville, ON www.ajmixing.comEmail:lyndon@ajmixing.com 800-668-3470FAX:905-827-7288 Write In 414
Portable Flowmeter
Mount the ultrasonic sensor on the outside of a pipe and this new PDFM 5.0 Portable Doppler Flowmeter shows ow rate instantly. Use it for ow troubleshooting, spot checks or balancing ow.
Jefferson Stocks Stainless Steel Valves

Same day shipping on all valves we have in stock including stainless steel and brass solenoid valves. Jefferson stocks ALL seat materials such as EPMD, FKM, PTFE AND BUNA N. Cost-effective crossover done on all valves.
Dry Run Protection

New PMP-25 Pump Load Control guards against dry running, cavitation and overload. It monitors true pump power for maximum sensitivity while displaying power, trip points and delays.The4X-enclosureissmall enough to t on size 1 starters and can be door-, panel- or wallmounted. Free 30-day trial!
Greyline Instruments Inc.

105 Water Street, Massena, NY 13662 888-473-9546 www.greyline.com Email: info@greyline.com Write In 415
20225NE15thCt.,Miami,Fl33179 www.jeffersonvalves.com 305-249-8120 Write In 416
Jefferson Valves
Load Controls, Inc.

www.loadcontrols.com 888-600-3247
Write In 417
Thermal Gas Flow Measurement

Eldridge Products, Inc.s new ValuMass Series 400 is a lower cost option for thermal gas mass ow measurement in a compact design. The Series 400 congurations accommodate most installation requirements.
Linear and Rotary Control Valve Actuators

Rotork Process Controls Product Catalog features the companys new CVA line of linear and rotary control valve actuators. The line features auto calibration, continuous modulating duty and extremely precise accuracy.
Spherical Disc Valve

The P21 High Performance Spherical Disc Valve is designed to meet your demanding requirements for containment of solids, powders and slurries. Engineered for positive sealing in vacuum and pressure applications, the P21s original spherical disc design eliminates the source of valve wear.
Eldridge Products, Inc.

www.ValuMass.com 831-648-7777
Rotork Process Controls, Inc.

675 Mile Crossing Blvd., Rochester, NY 14624 www.rotork.comEmail:info@rotork.com 585-247-2304 Write In 418 Write In 419
Gemco Valve
301 Smalley Ave., Middlesex, NJ 08846 www.GemcoValve.com/seal 800-654-3626 Write In 420
OFS Type 2 Seal Model

MECOs OFS Type 2 seal model is ideal for blenders, mixers, cookers, conveyors and similar rotating equipment used in the food, pharmaceutical, chemical, plastics, metals and other bulk process industries. Sized for OEM and custom process equipment.
Tigerex Material Handling Hoses

Tigerex offers unique material handling hoses designed to dissipate static electricity via embedded copper grounding wires or use of anti-static PVC compounds. Clear construction materials allow for visual conrmation of material ow.
Solenoid Valves
Catalog details 2-way bronze and stainless steel solenoid valves 1/4 to 3 to control the ow of water, ammonias, fuel oil, gas, steam, brine, solvents, cryogenics and oxygen. Valves are available NC/NO, packless construction and continuousduty coils for all voltages.
MECO Shaft Seals

www.woodex-meco.com
Kuriyama of America, Inc.

www.kuriyama.com
Magnatrol Valve Corporation

67 Fifth Ave., PO Box 17, Hawthorne, NJ 07507 www.magnatrol.comE-mail:info@magnatrol.com 973-427-4341FAX:973-427-7611 Write In 422 Write In 423
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Classifieds
Connect
43
Find featured products company websites and get free information at:
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www.ProcessingMagazine.com
www.globalprocessingmag.com
ProcessFlowDirect
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We can picture your ad here!

For more information, contact Liz Zane at Liz@grandviewmedia.com
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Coming in the next issue of Powder Handling Solutions!

Controlling Explosion Hazards of Dust Collection Systems Vahid Ebadat, CEO of Chilworth Global North America, explains common options for ensuring the safety of dust collection systems. Bulk Bag Handling System Slashes Carbon Black Inventory Elastomer manufacturer Kirkhill-TA slashed inventories of carbon black by 90 percent and improved plant cleanliness by replacing a large silo storage system with a bulk bag discharging system.
www.processingmagazine.com
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Find featured products' company websites and get free product information at www.ProcessingMagazine.com/freeinfo.
Index
Advertiser Index
Adalet ...................................................... 32 A & J Mixing ........................................... 37 Assmann Corporation of America .......... 10 A-T Controls, Inc. ....................................... 7 Atlantic Coast Crushers ............................ 6 Baldor ......................................................... 1 Benko ....................................................... 37 BinMaster Level Controls ......................... 40 Boerger .................................................... 11 Bredel Hose Pumps.................................. 13 Bunting Magnetics .................................. 24 Caplugs .................................................... 29 Cardinal Scale Manufacturing .................. 22 Carter Day ................................................ 30 Cashco ....................................................... 4 Charles Ross & Son Company ................... 5 Chemineer ................................................ 24 CST Industries .......................................... 16 Federal Equipment................................... 34 Fenwal Inc. ............................................... 31 Franklin Miller, Inc. ................................... 10 Gamajet .................................................... 40 Grainger ................................................... 33 GreCon ..................................................... 32 Halogen Valve Systems ............................ 34 Hannay Reels ............................................ 28 Hapman .................................................... 19 IKA Works, Inc. ........................................... 9 Inpro/Seal ................................................. 17 Jefferson Solenoid Valves .......................... 8 Kason Corporation ................................... 36 K-Tron....................................................... 25 Load Controls ............................................. 6 Lutz Pumps Inc. ........................................ 32 Magnetrol ................................................. 15 MasoSine Process Pumps ........................ 13 Material Transfer & Storage..................... 21 Neptune Chemical Pump Co. .................. 12 NETZSCH ................................................. 37 NPE ......................................................... 43 Omega Engineering ....... Inside Front Cover Orion Instruments .................................... 23 Plast-O-Matic Valves ..................Back Cover Practical Pumping .................................... 37 PTXi .......................................................... 39 Pump Symposium .................................... 38 Schenck AccuRate .................................... 26 seepex, Inc. .............................................. 18 Specialty Equipment .................................. 3 SPX Flow Technology ..... Inside Back Cover Stedman Machine Co............................... 18 Super Radiator Coils ................................ 30 Swagelok .................................................. 14 Tel-Tru Manufacturing.............................. 36 Triple S Dynamics..................................... 27 Union Process........................................... 36 Vac-U-Max ................................................ 35 Woodex Bearing Company, Inc. .............. 12
Product Index
Compressors
Almasi Column 12
Advertising Representation
ike Wasson, Publisher M Ph: 973-539-7715 Fax: 205-408-3797 Email: mikew@grandviewmedia.com
Plant Maintenance & Safety

Banner Engineering Front Cover Generation Systems 30 Halogen Valve Systems Inc 32 Pfannenberg Inc. 32
Food Equipment
Eaton Ingredient Masters NuTEC Manufacturing Sensorex Solimar Pneumatics 26 20 28 28 28

ACS Valves Front Cover Cleveland Vibrator Company 39 Flexicon Corporation 38 Great Western Manufacturing 39 Kason Corporation 39 Material Transfer & Storage 38 Munson Machinery 38
Instruments
Banner Engineering 36 Dwyer Instruments 37 KEYENCE Corp. of America 37 Sierra Monitor Corporation 36 VEGA Americas Inc. Front Cover Weidmuller 37 Yokogawa Corporation of America 36
ay Haas, District Manager J Ph: 205-572-1058 Fax: 205-408-3797 Email: jay@grandviewmedia.com
Pumps & Seals

Edwards 16 ITT Goulds Front Cover KNF Neuberger Inc. 14 Mackay Column 18 Moyno, Inc. 14 Trelleborg Sealing Solutions 16 Watson-Marlow Pumps Group 16 Wilden Pump & Engineering Company 14
ElizabethZane, Account Manager Ph: 205-408-3736 Fax: 205-408-3797 Email: liz@grandviewmedia.com

Charles Ross & Son Company 8 Chemineer 10 IKA Works, Inc. Front Cover National Bulk Equipment Inc. 8 Neptune Mixer Company 10 Stedman 8 Westfall Manufacturing Company 10
Tanks & Vessels

Assmann Corporation of America 40 CST Industries 40
200CroftStreet,Suite1Birmingham,AL35242 Ph:888-431-2877Fax:205-408-3797 SubscriptionInformation: Mail: P.O. Box 2174, Skokie, IL 60076-7874 Phone: 866-721-4807 E-mail: processing@halldata.com Change of Address: www.processingmagazine.com/subscribe
Plant Automation
Electro-Chemical Devices 29 McCrometer 29 Omega Engineering 29
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February 2012

SOLUTIONS FOR THE PROCESS INDUSTRIES

Mixing & Size Reduction

Rotary Feeder for Bulk Material Handling

IKA Works, Inc. 800-733-3037, www.ikausa.com

ACS Valves www.acsvalves.com

Work Light Strip

Next Generation Slurry Pump

ITT Goulds www.gouldspumps.com

Banner Engineering www.bannerengineering.com

E-News: Like us:

Sign up for Processing newsletters.

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12 Horizontally-Split Centrifugal Compressor Conguration

20 Sustainable Food Packaging Solutions

26 Better Safe Than Sorry!

30 Getting Serious About Lubrication

34 The Importance of Thorough Mixing

Editors Column Mixing & Size Reduction

14 Pumps & Seals 28 Food Equipment

A line of industrial sounders from Pfannenberg is spotlighted.

NickPhillips, Managing Editor nphillips@grandviewmedia.com Follow me on Twitter @ ProcessingMag

Reader Advisory Board

February 2012 www.ProcessingMagazine.com

MAKE: An American Manufacturing Movement

February 2012 www.ProcessingMagazine.com

Mixing & Size Reduction

Automated Bulk Material Mixing System

Charles Ross & Son Company

National Bulk Equipment Inc.

February 2012 www.ProcessingMagazine.com

Mixing & Size Reduction

Variable Flow Static Mixer

Neptune Mixer Company

Westfall Manufacturing Company

Impeller Designed to Prevent Fibrous Material Buildup

February 2012 www.ProcessingMagazine.com

February 2012 www.ProcessingMagazine.com

www.ProcessingMagazine.com February 2012

Pumps & Seals

Customized Solution for Exothermic Reactions

KNF Neuberger Inc.

Air-Operated Double-Diaphragm Pump Technology

Wilden Pump & Engineering Company

February 2012 www.ProcessingMagazine.com

Pumps & Seals

Trelleborg Sealing Solutions

Pump for Lime Slurry Applications

Watson-Marlow Pumps Group

Chemical Dry Vacuum Pumps

February 2012 www.ProcessingMagazine.com

Pumps & Seals

February 2012 www.ProcessingMagazine.com

Sustainable Food Packaging Solutions

February 2012 www.ProcessingMagazine.com

February 2012 www.ProcessingMagazine.com

February 2012 www.ProcessingMagazine.com

Self-Cleaning Water Filters Help Bagel Maker Improve Safety

February 2012 www.ProcessingMagazine.com

www.ProcessingMagazine.com February 2012

Metal Detectable Fluidizer Disk

February 2012 www.ProcessingMagazine.com