Roll Compaction System Rebuild and Upgrade:
A chemical company had been utilizing a roll compaction granulation system for one of their product lines. This product had unique characteristics and the chemical company did not wish to take a chance on adversely affecting these characteristics by replacing their roll compactor. The roll compactor had gotten so old that the original vendor would no longer provide support. Over the years the chemical company had tried to maintain the system on their own, but without much success. The system eventually became so undependable that it began to threaten the product line’s viability.
CGI was contacted by the chemical company to determine if we could provide the equipment support they need. We went to their site to investigate the situation and observed the following:
§ System gearboxes and drives had been incorrectly modified and rebuilt.
§ Material conveying systems were totally inadequate.
§ System automation was minimal and ineffective.
CGI along with our sister company Kinetic Process Design and Mechanical suggested the following action plan:
§ Provide temporary system repairs to allow the roll compaction system to be operated while a complete system overall project was developed.
§ Redesign system gearboxes and drives with current industry standard components.
§ Redesign roll compactor feed screw and feed hopper.
§ Redesign conveying systems to allow for required material flow rates.
§ Provide a system automation package that would allow for better process control and product quality.
Kinetic Process Design and Mechanical was given the go ahead to execute their plan and ultimately provided the customer with an extremely dependable fully automated roll compaction granulation system. With completion of the project the customer was also given a complete documentation package containing equipment manuals, design drawings, P&ID’s, and electrical schematics. In addition to providing the customer with a dependable roll compaction system we were also able to quadruple the systems production rate.
Today Kinetic Process Design and Mechanical is currently designing new roll compaction system for this customer.
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