Process Equipment: Flexible Solutions for Cooling and Solidification Systems

 

What Exactly is Process Equipment?

Process Equipment is an umbrella term for our solidification and cooling systems. The total package includes single or double belt coolers, corrosion-resistant steel belts, feeding devices, and discharging devices such as product breakers that process the applied material into flakes and blade assemblies to remove the pastilles from the steel belt. Process equipment is utilized to solidify molten products, enabling their safe transportation and seamless integration with other materials for further processing.

A Sophisticated Cooling Process

Berndorf Band Group’s single and double belt coolers equipped with steel belts are used around the world in many production processes to solid liquid products into different shapes. We employ an indirect cooling process which effectively dissipates the heat given off by the product to accelerate solidification of the material. Extra cooling zones can be individually adapted to ensure a controllable cooling process. Our cooling and solidification systems thus guarantee that the material is cooled down to the required process temperature. In this way, products that meet our customers’ demands can be manufactured economically and exactly.

No Contact Between the Product and Water

All of Berndorf Band Group’s Cooling Systems are supplied from the factory with quick-release nozzles that have a large orifice. These spray cooling water in a square spray pattern during the cooling process. This ensures maximum-efficiency and maintenance-free cooling. Finally, solidification of the liquid material on the steel belt takes place through the cooling caused by the cooling water sprayed onto the underside of the steel belt. The vee ropes at the belt edges form an additional drip edge in addition to the sliding seals further inside. Contact between cooling water and product is prevented by this specially developed Berndorf design. An environmentally friendly process with Berndorf Band Group cooling systems.

This gives steel belt solidification and cooling systems three key advantages:

1. The product is not in contact with the spray water.
2. The cooling water is not contaminated.
3. The cooling water can be reused for further processes, which significantly reduces the water consumption of the cooling process.

Cooling & Solidification Systems from Berndorf Band Group

Process equipment combines single or double belt coolers, steel belts, feeding- and discharging devices to form a complete package. The right combination of the individual components is crucial to achieve the optimal result for every customer. From Steel Belts and Belt Systems to global Service for turnkey systems, we provide an all-in-one solution:

Steel Belts

Choosing the right material for your Steel Belt is crucial. That’s why, following extensive research and development, we have developed special steels to meet the high demands of the chemical industry. These steel belts withstand the constant dynamic loads over a long period and are characterized by the following advantages:

• Optimum flatness & straightness due to special production method
• High-alloyed steel materials for corrosion resistance
• High dynamic fatigue strength resists deformation
• Perfect adhesion of vee-ropes
• Smooth Surface

Feeding Devices

Many of our Feeding Devices have been developed to satisfy a wide range of requirements. For example, they enable the production of products from low to high viscosity at a melt temperature of up to 250 °C | 482 °F. Various innovative Feeding Devices from Berndorf Band Group are available:

BernDrop® with Refeed Bar

• Low to high viscosity products (~150 – 50,000 mPa.s)
• Smooth shell and refeed bar
• Best for products that tend to stick to the shell

BernDrop® with Raised Shell

• Low to medium viscosity products (~2 – 5,000 mPa.s)
• Special geometry of the raised shell, no refeed bar
• Lower maintenance due to the reduction of wear parts

Casting Box

• Low to medium viscosity products (~2 – 5,000 mPa.s)​
• Vertical gate to regulate product thickness
• Typically used for thin products with low melting temperatures

BernFlow®

• Medium to high viscosity products (~1,000 – 50,000 mPa.s)​
• Adjustable horizontal knife at bottom of device to regulate product thickness
• Closed vessel to avoid oxidation of product

Overflow Weir Feeder

• Low to high viscosity products (~150 – 10,000 mPa.s)​
• Simple and cost-efficient device which is easy to clean
• Product thickness controlled by product feed pump

What Products can be produced using our Cooling and Solidification Systems?

• Process Equipment is used for the following materials:
• Waxes, such as cosmetic waxes (depilatory wax), hydrocarbon wax, paraffin wax
• Chemical products, such as aluminum sulfates, adhesives, hot melts and more
• Black substances, such as bitumen, asphaltene, tar and much more
• Sulphur pastilles oft he highest quality according to SUDIC standards
• Fertilizers, such as Sulphur and Bentonite, nitrogen derivatives, and more
• Oleo Chemicals, such as fatty alcohol, fatty acids, amides, amines, esters and stearines, surfactants (detergents), Polyethylene glycols (PEG), and more
• Resins, such as hydrocarbon resin, epoxy resin, acrylic resins and more
• Powder paints such as functional (Epoxy based), decorative (Polyester based), Decorative (Polyester-expoy based) and other powder paint raw materials