MATERIALS HANDLINGAND COOLING EXPERTS
PRODUCTS Materials Handling Cooling Equipment System Control Panels Pumps Heat Exchangers Granulators Pneumatic Conveying
SERVICES Design Installation Maintenance Spares Energy Saving 3 Year Warranty Equipment Hire
ABOUT USAB Systems specialise in market leading materials handling and process cooling systems, and is the first UK ancillaries company to
provide both stand-alone and integrated solutions. Experts in system design, installation, maintenance, and supply, we deliver bespoke turnkey solutions that are proven to significantly increase system performance, efficiency and reliability. In fact, our clients save an average of 50% on running costs thanks to our innovative solutions. Established in 1993, we have over 20 years of experience in selecting the highest-grade products available on behalf of our clients. To this end, we are proud sole distributors for several world-leading ancillaries and cooling manufacturers including SB Plastics, Nova Frigo, Avian Granulator, Lorandi, and OMP. To further best serve our strong client base, we also stock a comprehensive range of equipment at our purpose-built facility in Buckinghamshire, allowing us to deliver effective solutions quickly and efficiently.
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INDEXMATERIALS HANDLING RECYCLING
PROCESS COOLING
COMPRESSED AIR
Belt Conveyors 03 09
03 09
03 09
04 11
04 11
05 11
05 12
05 12
06 12
06 13
06 13
07 13
07
15
15
15
04
Granulators
Big Bag Frames Pulverisers
Centralised Vacuum Filters and Pumps Shredders
Dosing: Volumetric Units Air Blast and Adiabatic Coolers
Granular/Powder Hopper Loaders Chillers
Material Drying Cooling Towers
Material System Control Panels Heat Exchangers
Metal Detectors Pump Tank Modules
Pneumatic Conveying Blowers Spares
Pneumatic Conveying Pipework Temperature Control Units
Screw Conveying Water Filters
Separators: Vertical and De-dusting Water System Control Panels
Silo Loading
07Vertical Mixers Treatment
Connection
Distribution
Dosing: Gravimetric Units
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MATERIALSHANDLING
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BELT CONVEYORS
BIG BAG FRAMES
CENTRALISED VACUUM FILTERS AND PUMPS
High quality and multipurpose, our conveyors can be equipped with different belts, including anti-static, and slats to fulfill a number of applications. Belt conveyors have adjustable legs as standard, can be fitted inside, or serve fixed angle presses or blow moulding machines. All models have anodised extruded aluminium profiles.
We supply a wide range of material discharge frames, built to the highest standards by industry leading manufacturer Lorandi Silos. The units can be manufactured for fork truck or crane loading and unloading by screw conveyors, gravity discharge or vacuum and pneumatic conveying systems.
Filters: Central system filters have standard vacuum break valves with optional blow down filter cleaning.Pumps: Conventionally driven side channel blowers can achieve differential pressures of up to + 300mbar. In frequency-controlled operations, side channel blowers can be used for vacuum conveying up to –400mbar.
RANGE
Horizontal and inclined conveyors S Line conveyors Robot automatic operations Spiral/blade separators Stocking and weighing systems Metal detection systems
TECHNICAL FEATURES
PU or PP belt smooth or vulcanisedbelt joints Max temperature resistance -20/+100°C Geared motor coupled directly to thedrive roller with safety slipper clutch Robotic interface or photo cellrecognition options Automatic belt tensioner Standard or anti-static belts with arange of different slats to suit allapplications
RANGE FILTERS
Models FAT - M, P, G High temperature units
RANGE PUMPS
Side channel Rotary claw Rotary vane Positive displacement
TECHNICAL FEATURES FILTERS
Easy to remove dust bin Easy maintenance Spiral filter blowdown cleaning Vacuum break valve Paper, polystyrene or metal mesh filters
TECHNICAL FEATURES PUMPS
Air flow 80 mᶟ/hr to 1120 mᶟ/hr Ultimate vacuum of 60mbar to 500mbar 240v 1ph / 415v 3ph 1.8kW - 37kW
TECHNICAL FEATURES
Materials can be conveyed by ‘vibration’,‘screw’, or ‘gravity’ Fully controlled weigh cells with full datalogging for material usage options Discharge bins available in eitheraluminium or stainless steel Low level sensor options 60 degree cone for poorly flowingmaterials
RANGE
Big bag unloading Powder, granular or flake material Weigh cells Screw feed discharge Forklift loading Crane loading
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DOSING: GRAVIMETRIC UNITS
DOSING: VOLUMETRIC UNITS
Volumetric units are suitable for granular masterbatch and additive dosing in extrusion or injection processes within the plastic industry. Digital regulation and easy control display with brushless step motor. Memory programmable recipes and RPM link control from machine screw back signal.
Single Phase Hopper Loaders have an internal vacuum motor to draw material up the flexible hose to the machine hopper until it is full. Three Phase Hopper Loaders have a separate external three phase vacuum pump to transport higher throughput material over a larger distances.
Range of more than 60 dosing units for production from 25 to 5000Kg/hr high performance models in modular format. High precision mixing manufactured in stainless steel. All units are provided with dynamic mixers for homogenous mixing including automatic cleaning options, auto or manual bypass and shut off valves. Memory programmable with data and recipe memory for ease of use. Ease of mounting with floor mounted or machine mounted options with level sensors and site glass to assist operators.
RANGE 40 models or bespoke system design High temperature models Standard or bespoke controls availablewith high accuracy dosing software Recipes in percentages Auto easy drain and automatic cleaning High throughput flake blending Floor standing or machine mounted Built-in material level sensors
TECHNICAL FEATURES Accurate Masterbatch control of 0.01% Throughput of 25 - 5000Kg/hr Batch sizes of 0.5Kg - 25Kg per chamber Hopper capacity 5 – 50Ltr Mixer capacity 1 – 25Ltr 2 to 10 material chambers
RANGE
Injection and extrusion 3 models - Colour 1, 2, and XT Throughput of 0.08g - 120Kg p/h Standard or bespoke throat adaptors
TECHNICAL FEATURES
Screw sizes 12mm - 24mm Screw pitch 8mm Brushless motor Hopper capacity 4Ltr - 8Ltr -15Ltr 60dB 230v / 50Hz
GRANULAR/POWDERHOPPER LOADERS
RANGE
Single Phase 240v Three Phase Loaders 415v Centralised system loaders 24v Control 3litre -150Ltr capacity 5 - 4500Kg p/h throughputs
TECHNICAL FEATURES
Stainless steel construction Standard Microprocessor Control Remote control options Low noise < 80 dBa
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Designed to remove moisture present in polymers before they are processed. The series ranges from 30lt to 5000lt with air flows from 40 mᶟ/h to 2000 mᶟ/h.Robustly manufactured with easily accessible filters for an extended and cost effective service life. Standard over temperature alarms and safety features.
Standard panels are designed to control material loaders, vacuum pumps, central filters, metal detectors and line cleaning, and selection valves for small or multi-site applications. With simple to use programmable graphic displays, the panel display names can be custom-ised to the users’ machine and material source designations.
Upon detection of metal, the unit immediately stops material movement before discharging contaminated material out of the hopper and cyclone while blowing air inside the detector to ensure contamination is cleared. The unit’s pneumatic valve will then reset to default position, and the loading process restarts.
RANGE
External pipe diameter 50 – 70 mm Maximum Throughput – 50Kg-1000kg/hr Sensitivity range – 0.6mm FE, 0.7mm ALU,0.8mm SS
TECHNICAL FEATURES
High quality stainless steel mechanicalparts Compact and robust design Simple commissioning and operation Inspection flap for cleaning Complete separation of metals
RANGE
6 to 72 machine Multiple vacuum pump and filter Before and after line cleaning Ratio valve options
TECHNICAL FEATURES
HMI touch screen control Easy to programme Security password levels Remote Wi-Fi tablet or LAN control options SMS Text alarm messaging options
RANGE
Desiccant and hot air dryers Range of sizes to suit all drying applications Machine mounted or stand alone
TECHNICAL FEATURES
Dew point to -55°C Temperature ranges 50°C to 180°C Microprocessors PLC system Accurate temperature control Low energy consumption Air/water process heat exchanger
MATERIAL DRYING
MATERIALSYSTEMCONTROL PANELS
METAL DETECTORS
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Our Blowers are suitable for pneumatic conveying up to 4,000Kg per hour, and can be fitted to different applications. High air volume means granular materials with specific density of 0.2-1 Tmᶟ can be conveyed. Full range available including some models manufactured in stainless steel.
Our pipework is available in galvanised or stainless steel with optional ceramic wear proof surface treatment for abrasive materials or insulated for noise reduction. Modular design bends, branches, diverters, cyclones, filters, silencers, and outlets connect together with quick release or bolted air tight clamps to minimise air losses.
Bespoke or modular tube and screw sections manufactured in carbon steel then powder coated, with standard inlet and outlet spouts with smooth internal surface to prevent material hang ups.
PNEUMATICCONVEYINGBLOWERS
RANGE
Galvanised or stainless steel Diameter 100 - 270mm Full range of bends 15°- 90° Insulated and or lead lined Injectors or rotary valve High pressure blowers
TECHNICAL FEATURES
Painted, galvanised or stainless steel finishes Permanent or quick release joiningclips Pipe sections 60mm to 2000mm Positive or negative conveying
RANGE
Full range of silencers Regulation diaphragms Aluminium, galvanised and fullyreinforced stainless versions 100 – 180mm bore connection
TECHNICAL FEATURES
Up to 4,000Kg per hour 0.55kW to 11kW motor power Air volume 500 to 3000mᶟh
PNEUMATICCONVEYINGPIPEWORK
SCREWCONVEYING
TECHNICAL FEATURES
Discharge flange options Heavy duty end bearings and shaft seals Helicoid screw flighting on welded on centre pipe
RANGE
6 tube diameters Different angles and lengths available Carbon or stainless steel Direct or reduction gearbox drive
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Units designed to easily and effectively clean dust from materials or separate materials with different specific gravities. Larger particles are discharged from the bottom of the units while dust/smaller particles travel in the blown airflow to a filter system or collection bag. Manufactured for throughputs from 50 to 8000kg/hr, units deliver everything from preclean-ing to superior separating of materials
These units allow material to be loaded quickly and easily into silos from any source. They are fitted with durable positive displacement pumps and can load materials in silos up to 60mts high.
Mixers are built with an internal screw and access door for maintenance. Motors range from 1kW - 25kW depending on the material and design throughput. Optional hoppers and pneumatic control for big bag loading, tubular screw for front loading, and low level sensors for screw control.
SEPARATORS:VERTICAL ANDDE-DUSTING
TECHNICAL FEATURES
Steel and stainless steel options Viewing panels to allow fine tuning of airflow Simple to adjust for materials with different specific gravities or dust content Large access panel for cleaning Varying methods of loading material Static or telescopic supporting frames
RANGE
0.25 - 1.0 kg/dm3 material densities 50 - 8000kg/hr throughputs 0.37kW – 11.0kW blower options Regulation valves Pre-cleaning to complete cleaning systems
SILO LOADING
VERTICAL MIXERS
TECHNICAL FEATURES
Up to 60m conveying height 4 - 20 Tonne p/h throughput Loading application with bag frame Soundproof version available Sack loading Forklift loading
RANGE
Tanker, bag or box discharge Rotary valve or venturi Positive displacement blowers Acoustic enclosures
TECHNICAL FEATURES
Easy to load material hopper Weigh cell control option Standard manual valve control Automatic valve control on request Painted RAL 5012 finish
RANGE
Galvanised steel Stainless steel Capacity 350 - 28,000 litre
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RECYCLING
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Highly efficient range of Granulators designed to boost production and improve efficiency. Granulator range includes heavy, medium, large, low and high speed, and soundproof models. Suitable for use in moulding, blow moulding, machine-side recycling and centralised recycling.
Highly efficient range of pulverisers with high speed rotation and automatic temperature control system. Suitable for use in moulding, blow moulding, machine-side recycling and centralised recycling.
Highly efficient, energy saving range of shredders are available in single, double, and heavy duty single shaft versions. Suitable for use in moulding, blow moulding, machine-side recycling and centralised recycling.
GRANULATORS
PULVERISERS
SHREDDERS
TECHNICAL FEATURES
Automatic feeding Hydraulic connector and cylinder Safety locking device ‘X’ design rotor achieves excellentgrinding results Reduced noise output and noise insulation Safety lock switches Energy Saving
RANGE
Block, Film Sheet, Plastic and Rubber 4 – 5,000 Kg/hr output Motor power range 1.5 – 400 kW Cutting Chambers 300mm - 6000mm 2 – 488 Rotor knives Blower power range 1.5 – 45kW Screen holes 3 – 50mm diameter
TECHNICAL FEATURES
Space saving internal hydraulic device Overload control Safety locking features and switches Closed seal for excellent noise reduction Energy-saving ‘V’ design shredder rotor
RANGE
Motor output 7.5 – 600kW Double shaft hopper capacity0.6 – 1.6 m2 Cutter thickness 10 – 500mm Rotor speed 70 – 120 rpm 58 – 140 rotor knives Screen holes 50 – 100mm
TECHNICAL FEATURES
Automatic feeding system Automatic temperature control Pressure and flow control Manometer Easy access to outer observing holefor disk gap adjustment
RANGE
37 – 75 kW LDPE 120 – 500 Kg/hr H – PVC Granules 150 – 700 Kg/hr Motor output range 55 – 300kW DC53 steel cutting discs
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PROCESSCOOLING
ENERGY SAVING EXPERTS
3 Year WarrantyIndustry leading warranty and aftercarepackages for new and existing chillers
Innovative 24/7 alarm monitoring
GSM text alerts to your engineers for all alarms
Cost-effective, low one-off payments
Fully FGAS compliant
Full FGAS traceability
Highly qualified and experienced in-house service engineers
Unrivalled customer support
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Our air blast free coolers are supplied by world-leading manufacturer Nova Frigo. Used for hydraulic cooling or to assist chillers when the ambient temperature is low, free air coolers are extremely efficient and can achieve up to 80% energy savings. Return on investment is typically less than 24 months.
Our range of air and water cooled chillers are built to the highest standards by industry leading manufacturer Nova Frigo. All chillers deliver high efficiency and very low power consumption with excellent EER/COP values, even in extreme tropical climates with ambient temperature up to +45°C.
We supply a wide range of cooling towers, built to the highest standards by industry leading manufacturer Evapco. The units are reliable, easy to maintain, and are designed to reduce manufacturing costs.
AIR BLAST ANDADIABATIC COOLERS
CHILLERS
COOLING TOWERS
TECHNICAL FEATURES
Non-clogging water distribution nozzles Highly efficient pack and fill withlow pressure drop Sloping self-draining pan with strainer Smooth flow low sound fans Easy access cleaning doors Maintenance platforms and fanremoval davits
RANGE
Induced or forced draft models Galvanised or stainless steel Axial or radial fans Low noise models Up to 10MW duty
TECHNICAL FEATURES
Multi chiller central PLC panel controloptions Ultra efficient evaporator and condenserdesign Internal water filter Multi-function Microprocessor PLCcontrol 3.5 - 4.5 - 5.5 bar pump options R407c refrigerant
RANGE
2kW - 1000kW cooling capacity units Internal or external applications Modular and stand alone with remotecontrol options Water or air cooled units Energy efficient with excellentEER/COP values
TECHNICAL FEATURES
Efficient fan motors Low 40dBa noise units Polyester coated frame construction
RANGE Small footprint, low profile 10kW – 1000kW cooling capacity Variable fan speed options Horizontal or vertical models Adiabatic cooling options
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We offer a complete range of efficient Plate Heat Exchangers for chilled water, oil, or air heat transfer. These can be supplied to replace existing heat exchangers, or manufactured as a unit with pumps, tanks, and temperature control valves.
Our tank modules are suitable for all process applications with flow rates from 10 and 260m3/h. Units can be made with single or multiple end-suction or in-line pumps, including high pressure models, and come complete with mains cold water make up, drain valves and overflow pipes.
We stock thousands of spare parts (including universal parts) from a wide range of suppliers at our purpose-built facility in Buckinghamshire. This means that we can process orders quickly and efficiently, and often provide next day delivery. Our spare parts come with a 12 month manufacturing guarantee.
HEATEXCHANGERS
PUMP TANK MODULES
SPARES
TECHNICAL FEATURES
Standard plates: 304 & 316 Stainlesssteel / titanium / hastelloy Gaskets: Nitrile / EPDM / viton - all gaskets are clip-on type Connections: BSP threaded / flanged / hygienic (RJT, Tri-Clamp etc) Frames: Painted steel for non-hygienicapplications - stainless steel for hygiene
RANGE
Demountable plate Brazed plate Shell and tube 10-1000kW units Stainless steel or titanium
TECHNICAL FEATURES
Bespoke designed for any system size Tank over pump for small footprint Durable construction Insulated tank for energy efficiency
RANGE
Weir or break tank models GRP or stainless steel tanks 250 - 9000Ltr single piece tanks Galvanised fabricated box-sectionsteel frame
RANGE
Electrical parts Dryer, hopper, and chiller spares PCB boards, probes, temperaturecontrollers Seals and filters Hydraulic hoses BSP malleable, PVC plastics, pipeworkand air fittings
TECHNICAL FEATURES
Next day delivery often available Thousands of parts in stock Range of equipment manufacturers Full range of materials handling andcooling parts
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Our wide range of water and oil temperature controllers are built to the highest standards by industry leading manufacturer Nova Frigo. All of our precision temperature control units feature innovative and advanced technologies to provide exceptional reliability, energy efficiency, performance, and reduced maintenance.
A comprehensive process filtration range covering filter cartridges, housings and bag filters for single point of use applications or complete system multi unit filtration systems.
Our water system control panels are designed to control all aspects of cooling systems - including chillers, cooling towers, pumps duty, stand-by switching and pressure control, tank level control, and self-cleaning filters, to name but a few - in the most economical and efficient way.
TEMPERATURECONTROL UNITS
WATER FILTERS
WATER SYSTEMCONTROL PANELS
TECHNICAL FEATURES
PID control for heating and cooling Indirect or direct cooling Automatic filling Flow rate control options Pressurised hydraulic circuits for hightemperatures
RANGE
9 - 36kW heating Water and oil units 90ºC to 250°C units Indirect / direct circuits
RANGE
Plastic, carbon or stainless steel Single or multiple filters Self-cleaning units Cartridge or bag elements Flows to 4000Ltr p/m Elements to 5micron
TECHNICAL FEATURES
High quality rugged construction V band or swing bolt closures Drain and bleed valve options Up to 20bar pressure rating Flanged or bsp connections
TECHNICAL FEATURES
HMI touch screen control Easy to programme Security password levels Remote Wi-Fi tablet or LAN controloptions SMS Text alarm messaging options
RANGE
Single pump to multi-site applications Energy saving control Inverter drive PID loop control
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COMPRESSED AIR PARTS
AB Systems offers a comprehensive range of energy efficient compressed air products suitable for fluid and air applications in all industries, using pneumatic and hydraulic energy. Characterised by high build quality and innovative design, our products ensure optimum air flow while preventing significant pressure loss. As a result, users will benefit from long-lasting reliability, minimal maintenance, and reduced energy costs.
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PULVERISERS
TREATMENT
CONNECTION
DISTRIBUTION
Air treatment units ALTOSub-micron filtersRefrigeration dryers
Absorption dryersDrains and separatorsCondensation processing units
Push in fittingsSafety quick couplingsStandard quick couplingsHydraulic quick couplings
Water circuit couplingsCompression and olive fittingsValves
Composite alloy piping PVRHose reelsHose extensionsSpirals
Washing gunsBlow gunsBalancers and energy boxesSuspension arms
INSTALLATION AND COMMISSIONING
SERVICES
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DESIGN
Our wealth of experience in the management of complex manufacturing projects enables us to design bespoke
solutions that deliver the highest levels of efficiency and performance. Following a full site survey, which includes detailed reporting and solution options, plus an energy
saving proposal, we provide a feasibility study and initial conceptual design, progressing through to detailed CAD
design and approved-for-construction documentation.
By keeping the design and construction phase of a project in-house, we are able to reduce delivery schedules, and offer flexible installation options, such as weekend and
evening work, to minimise disruption to production processes. This ensures that our clients receive the most cost-effective
and efficient solution possible.
MAINTENANCE
To ensure business continuity, we provide a comprehensive range of planned preventative maintenance contracts, all
delivered via our highly trained in-house engineers. Furthermore, our thorough system checks detect mechanical wear or
defects long before any problems arise, preventing issues and ultimately prolonging equipment longevity.
ENERGY SAVING
Thanks to intelligent design, excellent product specification, and a range of specialist energy saving equipment, our
solutions deliver the highest levels of system performance and energy efficiency, and have proven to help our clients
save an average of 50% on running costs. What’s more, we provide an accurate energy saving proposal with initial
quotations.
PROJECT MANAGEMENT
In order to maximise the cost and time efficiency of every installation, our experienced project managers and highly
trained engineers take great care in providing intelligent and thorough project planning and organisation, ensuring that
resources are securely managed and maintained throughout.
We stock a full range of off the shelf spare parts at our Head Office, and can also provide bespoke parts manufactured to clients’ specifications. All spare parts come with a 12 month manufacturing guarantee, while newly installed equipment carries a 12 month parts and labour guarantee. We also
offer equipment hire on many of our cooling and materials handling products.
SPARES / EQUIPMENT HIRE
NOTES
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Unit 1 Wornal Park Menmarsh Road Worminghall Buckinghamshire HP18 9PH United Kingdom
Call: 01844 339 044Email: [email protected]: www.ab-ltd.co.uk
This document is non-contractual. AB SystemsLtd reserves the right to modify the features of its range without prior notice.
