June 20, 2008
1
FORBERG INTERNATIONAL AS
Presents
Forberg Twin Shaft Drying System
Forberg Twin Shaft Drying System
Contents of PresentationContents of Presentation
• Where used
• System & Process description
• Three Case Histories
• Drying of wheat
• “One Pot Processor”/ pharmaceutical process unit
• Drying of waste on cruise ships
June 20, 2008
2
Forberg Twin Shaft Drying System
Contents of PresentationContents of Presentation
• Where used
• System & Process description
• Three Case Histories
• Drying of wheat
• “One Pot Processor”/ pharmaceutical process unit
• Drying of waste on cruise ships
Forberg Twin Shaft Drying System
Where usedWhere used
• All branches of industry, mainly powders
• Drying of wheat, food waste and waste water on board of cruise ships, detergent powders,
pharmaceutical powders
• Various Food Industry:
• Potato starch
• Drying/ granulation of enzymes on flour
• Protein-rich by-products fish industry
• Various chemical powders, like:
• Welding flush powder
• Glass filter cake
• Catalyser powders
• Quartz sand
June 20, 2008
3
Forberg Twin Shaft Drying System
Contents of PresentationContents of Presentation
• Where used
• System & Process description
• Three Case Histories
• Drying of wheat
• “One Pot Processor”/ pharmaceutical process unit
• Drying of waste on cruise ships
Forberg Twin Shaft Drying System
Heart of all Forberg® machines: Heart of all Forberg® machines:
”Twin Shaft Mixing System””Twin Shaft Mixing System”
June 20, 2008
4
Forberg Twin Shaft Drying System
Main Principles Forberg Mixing…Main Principles Forberg Mixing…
Heart of all ForbergHeart of all Forberg®® machines: machines:
””Twin Shaft Mixing SystemTwin Shaft Mixing System””
Forberg Twin Shaft Drying System
Demand for effective drying: "Mixing of energy and product in thDemand for effective drying: "Mixing of energy and product in the best e best
possible way". possible way".
In which way: intensive movement of particles i dryer. In which way: intensive movement of particles i dryer.
..\..\FORBERG
PRESENTASJONE
R\Mixing.avi
June 20, 2008
5
Forberg Twin Shaft Drying System
Air Flow in the Forberg DryerAir Flow in the Forberg Dryer
Air inlet
Product outlet
Air outlet
Product inlet
Forberg Twin Shaft Drying System
Advantages of the Forberg DryerAdvantages of the Forberg Dryer
High thermal efficiency, app. 80 per cent.
Can operate close to the product’s maximum temperature,
increasing the drying efficiency.
Constant and controlled air supply.
Combined process possible: mixing of various ingredients,
spraying of liquids
June 20, 2008
6
Forberg Twin Shaft Drying System
Advantages of the Forberg DryerAdvantages of the Forberg Dryer
Stop and Go feature
In case of emergency shut downs, power failures or any other error, the feed
remains in the batch system and it can be re-treated while manually
controlling the process to the end.
Saving on additives
Any kind of heat sensitive additives such as vitamins, enzymes,
pharmaceuticals, medicines, colours and flavour can be added after the
treatment at normal temperatures thus saving on these expensive
components.
Forberg Twin Shaft Drying System
Limitations Limitations
The area in top of the mixer is a bottle neck. Largest capacity:
• app. 1700 kW heating power
• 38000 m3/h Air Flow
Typically used for processes with "lower and mid range
capacity" bulk drying
June 20, 2008
7
Forberg Twin Shaft Drying System
Contents of PresentationContents of Presentation
• Where used
• System & Process description
• Three Case Histories
• Drying of wheat
• “One Pot Processor”/ pharmaceutical process unit
• Drying of waste on cruise ships
Forberg Twin Shaft Drying System
Example of a Drying ProcessExample of a Drying Process
Drying of WheatDrying of Wheat
Batch 3 26.01.2002
0
20
40
60
80
100
120
Tid 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
min
Verdi
Produkttemp
Utluft
Rel %
InnluftRel %
Innluft
Produkttemp
Utluft
June 20, 2008
8
Forberg Twin Shaft Drying System
FTFT--350 Mixer 350 Mixer -- Granulator Granulator –– DryerDryer
“One Pot Processor”/ pharmaceutical process unit “One Pot Processor”/ pharmaceutical process unit
Forberg Twin Shaft Drying System
FTFT--350 Mixer 350 Mixer -- Granulator Granulator –– DryerDryer
“One Pot Processor”/ pharmaceutical process unit “One Pot Processor”/ pharmaceutical process unit
June 20, 2008
9
Forberg Twin Shaft Drying System
FT – 350
Machine number 2401
System number S45-01
Year of production 2001
Process time 30 - 45min
Maximum filling mixer/dryer 490 litre Nominal filling mixer/dryer 350 litre Lower filling mixer/dryer 180 litre
Rotor shaft speed 32-100 rpm
Components: Mixer
Filter
Frame mixer
Q-rohr DN600
Air-system
Nominal Operation pressure( Po) Atmosphere
Reduced explosion pressure
Volume of process chamber 2 349 litre
Forberg Twin Shaft Drying System
First, stage - Filling
The rotors are started. Product is filled
into the mixer chamber. Filling of the
mixer chamber is done by a pneumatic
conveying system via a Quadro-Comil.
Two different powders, lactose and
potato starch, in an approximate 60/40
division, are to be added.
While filling is performed two butterfly
valves close the pipelines from the
heater system into the mixer. This
hinders ingestion of unwanted powder
into the heating and condensation
system.
June 20, 2008
10
Forberg Twin Shaft Drying System
Second, stage - Mixing
Product valve is closed. The two
different powders, lactose and
potato starch, are mixed. Mixing
time may be as little as 10
seconds.
Forberg Twin Shaft Drying System
Third, stage – Spraying (Coating)
Coating of the powder is achieved by
spraying a liquid solution of binder/carrier
and active substance, onto the dry powder.
Spray pattern and droplet size is controlled
by type of nozzle (opening and angle),
applied pressure, time for spraying and
distance between nozzle and hit point.
A spray tank is filled with the
liquid. The spray tank is
pressurized by compressed air.
Correct spraying is enabled by
compressed air actuated, spray
nozzles. Spraying is actively
controlled.
June 20, 2008
11
Forberg Twin Shaft Drying System
Fourth, stage – Granulation
Granulation of the powder is achieved by the
liquid solution of binder and dry powder
which are “wet” mixed together. Multiple
stage spraying and wet mixing may be
necessary to build up granules.
Forberg Twin Shaft Drying System
Fifth, stage - Drying
The inlet air pipe butterfly valves are opened.
Warm, clean and dry air is blown into the
mixer chamber via the integrated side
funnels. Paddles bring the air through the
material and up in the fluidized zone.
The granules are slowly dried to the required
moisture content. Moist air and free
suspended particles flow up to the primary
filter. The primary filter, which is mounted
over the chamber, stops most of the free
suspended particles from flowing into the
return pipeline. The individual primary filter
pockets are cleaned by compressed air. The
separated particles fall back into the
chamber. Operating the vibrators in pre-
programmed pulses prevents unwanted build
up of powder on the walls.
June 20, 2008
12
Forberg Twin Shaft Drying System
The air continues through the door
to the secondary filter cassette. The
secondary filter stops 99.997% (0,3
µm particles) of the remaining
particles. Moist clean air continues
through a pipeline to the fan. The
fan blows moist air from the
secondary filter down into a coil
cooler. Condense from the
dehumidified air is drained out
beneath the droplet chamber.
Cold and humid air flows up into the
heater where it is heated and
returned to the process chamber.
Forberg Twin Shaft Drying System
Last stage - Discharge
Airflow is stopped. The air inlet
pipe butterfly valves are
closed. The system is run
through a final additional
cleaning cycle of the filter and
walls to allow all powder to
settle.
Product is discharged through
the discharge doors into the
discharge hopper. The rotors
are stopped.
From the discharge hopper
granules are transported by a
pneumatic conveying system
through the Quadro-Comil and
into containers.
June 20, 2008
13
Forberg Twin Shaft Drying System
General description of cleaning
The system includes an integrated
CIP nozzle system complete with
control valves and a customised
PLC system. The system enables
CIP (Cleaning In Place) of the
main process chamber and main
filter.
Due to the product qualities the
primary filter unit may need
additional manual cleaning.
The quick access and
exchange system of the
primary filter unit enhances this
manual cleaning. Tap water,
process water and detergents
supply and removal with
treatment are not included.
Forberg Twin Shaft Drying System
”Filter Unit with extractable Filter”
Example of ”Cleanability”Example of ”Cleanability”
June 20, 2008
14
Forberg Twin Shaft Drying System
Maritime Maritime –– Waste ManagementWaste Management
Forberg Twin Shaft Drying System
Drying of food waste and waste water on boardDrying of food waste and waste water on board
=> Burning in incinerator