Double Cone Blenders (DCB)
Double Cone Blenders (DCB)
DCB: Double Cone Blenders
S2 Engineering Industries (S2) specialises in providing comprehensive turnkey solutions for Double Cone Blenders (DCBs), encompassing every phase from design and manufacturing to assembly, installation, and commissioning.
Innovative Design
S2’s Double Cone Blenders are engineered to deliver superior mixing efficiency. The conical shape of the vessel ensures that as the blender rotates, the entire product batch is thoroughly mixed through an inter-folding process. This design maintains the integrity of sensitive products, making it ideal for applications in the Pharmaceutical, Food, and Chemical sectors. The conical shape also facilitates easy discharge and cleaning, optimising operational efficiency.
Turnkey Solutions
S2 Engineering offers a full range of turnkey services for our Double Cone Blenders, ensuring a seamless experience from initial design to final commissioning. Our solutions are tailored to meet specific client requirements, offering both capital and operational cost benefits while enhancing equipment versatility and space efficiency.
Optional Features
- Integral Drying System: Available as an option to integrate with Rotary Cone Vacuum Dryers (RCVDs).
Manufacturing Excellence
Our Double Cone Blenders adhere to the highest safety and quality standards, meeting all relevant industry regulations. S2 Engineering integrates advanced automation and control technologies to ensure precise operation and reliability.
S2 Engineering’s dedication to innovation and quality positions us as a leading provider of Double Cone Blenders, with equipment that complies with national and international regulations. Our commitment to excellence ensures secure and efficient operations across all processes.
Technical Specification
- Design & Construction: Manufactured to ASME Sec. VIII, Division I, Latest Edition
- Main Dimensions: Custom-designed to suit specific application requirements
- Flange Drilling: ANSI B16.5, #150
- Capacity: Typically supplied from 500 liters to 5,000 liters
- Operating Pressure: 0-6 Barg (0-90 psig)
- Operating Temperature: Ambient; drying systems available upon request
Design Features:
- cGMP Compliance: Designed and constructed to meet current Good Manufacturing Practice (cGMP) standards, ensuring high quality and reliability.
- Robust Construction: Features a double pedestal support for added stability and durability. Single pedestal versions are available for applications with limited physical space.
- External Bearings: All bearings are positioned outside the blending vessel to prevent contamination and facilitate maintenance.
- Non-Clogging Design: Engineered to prevent clogging, ensuring easy cleaning and consistent performance.
- Direct Drive Mechanism: Utilises a hollow shaft gearbox for torque transmission and speed reduction, eliminating the need for conventional belt pulleys, chain sprockets, or spur gears.
- Cantilever Support: Available for DCB models up to 1,000 liters, this support type saves space beneath the equipment and isolates the service area for improved accessibility.
- Complete Automation: PLC-based operation options are available for full automation and precise control.
S2 Engineering’s Double Cone Blenders are designed to offer exceptional performance and flexibility, tailored to meet your specific process needs while ensuring ease of maintenance and operational efficiency.
Dimensions
Supply Options
S2 Engineering offers a comprehensive range of supply options for Double Cone Blenders to meet diverse operational needs:
- Variable Speed Electric Motor Drive: Reduces energy consumption and enables smooth ramp-up operations.
- Dryer and Solvent Recovery Systems: Includes condensers, receivers, and vacuum systems for integrated drying and solvent recovery.
- Full Instrumentation Pack: For control room operation or DCS systems, ensuring precise control and monitoring.
- Clean Room Configuration: Available for applications requiring sterile environments.
- Operator Gantry and Staircase: Facilitates safe and convenient access to the equipment.
- Controlled Discharge System: For efficient and accurate product discharge.
- Powder Loading and Discharge Systems: Streamline the loading and unloading of materials.
- Barrier Isolator: Surrounds the entire system with an optional operator half-suit for safe product loading and discharge.
- Hot Water Washing Systems: CIP (Cleaning in Place), SIP (Sterilisation in Place), and WIP (Wash in Place) systems for thorough cleaning.
- ATEX Rated: Explosion-proof designs available to meet specific safety standards.
- Bespoke Guarding Systems: Including laser beam guarding for enhanced safety.
- Load Cells: To confirm accurate addition or discharge of product.
- Jacketed Cone Shells: Control the temperature within the cone shell for temperature-sensitive processes.
- Agitator Bars: Designed for high-intensity mixing to ensure thorough blending.
- CE and PED Compliance: Ensuring adherence to European safety and design standards.
Material Options:
- Alternate Materials of Construction: Available in various grades including 304, 316, and 316L Stainless Steel, as well as Alloy 20, Alloy 22, and Alloy C276 (Hastelloy C) for specialised applications.
- Chemical Resistant Coatings: StanCoat high chemical resistant coatings provide an economical alternative to exotic alloys for processing highly aggressive substances and are suitable for food-grade applications.
For bespoke solutions tailored to your specific needs, please contact us for further details.
Benefits
S2 Double Cone Blenders offer several key advantages:
- Minimal Attrition: Designed to minimise product media attrition, preserving the quality and integrity of the materials.
- Efficient Discharge and Cleaning: The conical vessel shape facilitates easy and effective discharge of materials and simplifies cleaning operations.
- Uniform Blending: Without scrapers, ploughs, scoops, or vanes to obstruct material flow, these blenders prevent clogging and ensure consistent, uniform blending.
- No Bearing Contamination: Bearings are external to the blending vessel, eliminating the risk of bearing fluid contaminating the product media.
Application
S2 DCB's are used in many industry sectors including;
- Pharmaceutics,
- Dyes/dye intermediates,
- Inorganic chemicals,
- Temperature sensitive materials,
- Plastics,
- Agrochemicals,
- Organic chemicals
Literature
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