Echelpoelweg KA Weerselo The Netherlands. Tel. (+31) Fax. (+31)

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1 Echelpoelweg KA Weerselo The Netherlands Tel. (+31) Fax. (+31) info@esico.nl

2 Enabling Simplicity in Construction About us Esico design and manufacture Process Belt Systems for mainly the chemical and food industry. We also have extensive know how of overhauling existing installations and optimizing capacity of process lines. Our many years of experience and know-how make our designs creative, ingenious and straight to the point, consequently being: Cost saving Reliable Easy to maintain Easy to clean Energy efficient cooling systems Our process line design is not only initially economic, our processes are also more energy efficient than our competition. Making your product cheaper to manufacture in the long run. Partnerships Esico is partnered to specialized companies working with the same mentality and standards to be able to offer solutions in all process areas. Steel belt systems We have many years of experience with steel belt tracking and handling. Esico designed a tracking system which operates fully pneumatic or hydraulic creating a system not so prone to faults. Esico innovates where the competition is on a stand-still. We care about our product and continue to improve creating well thought of end-products. Problem settler We offer a complete package, not only by acting as a reliable supplier but also as a professional who thinks along with you. A problem settler who knows what it s about and what a customer needs. We express this in the whole extension of our services. We are involved In our experience we have engineered many custom solutions. We can offer advise on manufacturing methods for your specific product requirements.

3 Cooling processes Cooling In any cooling process we use the principle of countercurrent flow. The cooling medium is flowing in the opposing direction of the hot medium (the product). Single belt water cooling Esico designed a system to cool steel belts energy efficient. Cold water is prayed to the bottom of the belt to cool the belt. The (hot) product on top of the belt is cooled by the belt. The coldest water is sprayed to the belt at the product outfeed. This water is pumped to the next cooling zone(s) until it finally reaches the last zone, located at the product load terminal. Recirculation of air The same concept can be used for air coolers. In this case air is recirculated. This offers a much better cooling effect compared to using air from the environment: Air temperature can be controlled Air humidity can be controlled Moisture can be drained to guaranty no water will be able to reach the product. The Esico design guarantees easy access to the cooling tunnel for cleaning and maintenance activities. Product direction Cooling medium direction Recirculation of water Esico designed a system where all water is recycled and reused inside the cooling belt. In this case the water is chilled by means of a heatexchanger. Double belt Esico manufactures double belt cooling systems for sheet casting with an innovative cooling design. Water is simply run over the top belt to cool the product from the top as well. This water simply flows from the belt sparing the cost needed for extra equipment such as (vacuum - ) pumps. Esico advantages: Energy efficient due to less pumps and other expensive pneumatics necessary to keep the cooling process running Economic due to a lower initial investment Esico advantages: This solution is: Energy efficient and sustainable. Greatly reducing contamination by an external water source and reduced risk of clogging of spray nozzles. Spraying conduits are installed lateral with a quick fit system prohibiting faulty assembly.

4 Typical cooling belt configuration Product infeed Esiform Pastilator Extruder Slab feeder Other Hood Hood with screens Simple economic hood Air-Cooling hood Freezing hood Product outfeed Pneumatic scraper Breaker Cutting equipment Flaker Water cooling system Water recycling system External water source Stainless steel belt Full stainless is our standard

5 Single belt design Belt tracking Esico manufactures a belt tracking system which operates fully pneumatic, or hydraulic whenever belt tension requires it. This tracking system works without any electronics and is purely mechanical. Roller supports Our rollers can be fit quickly and are designed to require no maintenance. The rollers have no bearings and do not need to be lubricated. Spraying conduits High quality PVC conduits, lateral assembled. Guarantees easy access and exchangeability. Esico designed a fool proof quick release system to exchange conduits whilst locking them in place. Ensuring an optimal angle and cooling effect. Belt wipers Belt wipers consist of three consecutive standard wiper blades. Cooling water handling Stainless steel pumps are positioned in the framework of the cooling belt to enable a compact machine design. Water connections are made using Tri-clamps to simplify maintenance activities.

6 Pastillation Pastillation Pastilles are used to produce (semi-) finished products in the chemical industry, pharmaceutics, food and cosmetic industry. Pastillation has many advantages -Dry process: the product in pastillated without the need of water -Continuous and high capacity process Esiform: high capacity pastillation Esico manufactures pastillation systems in order to fulfill the demand for high quality equipment with better maintenance and adjustments compared to the competition. This resulted in the Esiform pastillator design as it is manufactured today. The pastillating system is an economical, efficient and reliable system for the continuous solidification of hot liquids to dust free granulate. The formed pastilles have an ideal shape for: re-melting as a semi finished product. reliable transport in Bulk handling systems (such as bagging systems and bigbag filling stations). Working principle The Esiform Pastillator is a system where melted product is pumped through a static centre shaft. A tube with holes rotates around this shaft. Whenever a hole passes the liquid a drop is formed. The drops fall onto the steel band, solidifying as pastilles. Inside the static shaft is a labyrinth to divide the product evenly over any belt width. Product charesteristics Product melts with temperatures up to 300 degrees celcius can be pastillated with the Esiform pastillator. The viscosity of these products are gerenally between 1 and mpas. Known products which are very well able to be pastillated are: Hot melts Paraffin Waxes Fats Additives Aside from the viscosity other factors are also important, to truly determine if a product can be pastillated samples can be send to our factory or be produced at our pilot plant. Test facility We can test your product at our production facility. At our pilot facility we can run product tests on an Esiform pastillator in a flexible and small setting. We offer potential customers test runs of product at our small plant. Product runs with +/- 50kg of product are already feasible. This is ideal for: Product feasibility tests: can your product be pastillated? Prototype runs for pastillated product An example to manufacture your own pilot plant Getting a better grip on pastillation Meeting us and to allow us to introduce you to our solutions. Contact Esico for the conditions of product pilots and feasibility tests.

7 Esiform Pastillator Technical data Heated medium, standard up to 250 C, up to 300 C upon client requests. Pastillator can be heated with steam or thermal oil. Broad viscosity range 10 to mpas Stainless Steel AISI304 execution, AISI316 upon request. Suitable for any belt size Esiform High quality pastillation Continuous and high capacity solution: capacity from 50kh/h to 5000kg/h Dry and dust free no water contamination Construction suitable for food industry Main advantages Easy to dissemble and maintain Simple construction with, understandable and to the point adjustments. Ergonomic and maintenance optimized design Taylor made systems The Esiform pastillator can be made for client specific belt sizes, capacity and products.

8 Esiform Pastillator Open bearing construction Open Bearing construction to prohibit defects due to worn out seals and product leakage. Simple adjustments Simple construction with, understandable and to the point adjustments. Single bolt (dis-) assembly Fast and fool proof disassembly Ergonomic maintenance The pastillator can be rotated parallel to the cooling belt to enable easy maintenance in an ergonomic position. Simple and ergonomic safety hood Equiped with gas springs to ease opening

9 Esiform Pastillator Maintenance The Esiform pastillator is simple to clean, adjust and maintain, greatly reducing the time necessary for maintenance activities. The pastillator can be dismantled when it is simply rotated sideways to the cooling belt. This ensures that the maintenance engineer does not have to climb on top of the belt to replace wear parts. Identification of Main parts 1. Product infeed (swivel pipe) 2. Stator and Product Divider 3. Perforated tube 4. Refeed Bar 5. 1 Steam/thermal oil supply/outfeed Wear parts inside the Esiform are optimized for reducing maintenance costs, down-time and component costs. Usage of screws and bolts are minimized Optimal working position during maintenance activities Economic Description of main parts 1). Product infeed consists of a double sided and heated swivel pipe. The product is also filtered inside this pipe using a large basket filter unit. 2). The product is pumped through the stator and divided over the width of the pastillator. 3). A perforated tube rotates around the static axle. Whenever a hole passes the product a droplet is formed and falls down onto the belt 4). The Refeed Bar is feeding excess of product back into the product divider. Tightening the hand wheel will press the Refeed Bar tight to the perforated tube. 5). Steam of hot thermal oil is flowing through all parts ensuring that product stays liquefied inside the pastillator.

10 Esiform Pastillator Adjustements Angle of product infeed can be changed easily using a robust handle. The overall height of the pastillator can be adjusted using the support bolt. The stator can be rotated upside down in order to be able to clean nozzles without seals falling out of the stator. Simple, two bolts, adjustment of the Refeed Bar angle and height. The safety hood is equipped with gas springs to ease opening. The safety hood will lock in open position to keep it from falling down.

11 Esiform Pastillator The bearing house has an open construction in order to prohibit product from leaking into the bearing. There is a clear separation between the product side and the bearing side. Forcing product away from the bearing in case a seal is worn and starts to leak. Maintenance and cleaning The pastillator can be dissembled once rotated away from the cooling belt by releasing one bolt. Parts can be disassembled easily. The product divider strip simply falls out of the stator and can be dissembled by releasing 1 bolt. A large basket filter (1) is installed in the product infeed of the pastillator. The product filter can easily be cleaned and replaced. A flange (2) is installed on the bottom of the swivel pipe in order to drain and clean the pastillator. 1 2

12 Esiform Pastillator Wear and spare identification High temperature bearings Distance wear plates Side seals Refeed Bar seal Mechanical seals Product divider Nozzle seal