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Littleford Day Inc. Where Processing Ideas become Reality.

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Presentation on theme: "Littleford Day Inc. Where Processing Ideas become Reality."— Presentation transcript:

1 Littleford Day Inc. Where Processing Ideas become Reality.

2 Advance Drying with Littleford Units Littleford Day Inc.
Where Processing Ideas Become Reality.

3 Littleford Ploughshare Dryers. Presentation Index
Page Contents The “Fluidized-Bed” for better drying. Lump Breaking action. Drying in the Littleford. Stages of Drying. Heat Transfer Graphics. The Choppers action benefits when drying. How do we build them. Manufacturing Options. Regular Sizes. Optimizing Drying in the Littleford Drying heat sensitive low percent solids Typical Applications. 19 Rental Programs Service and Spare Parts. Technical Center: Our Lab. Facilities. Testing & Optimizing Products.

4 The “Fluidized Bed” Operation for Mixing & Drying:
Liquid dispersion is done by spraying liquids against fluidized powder, by Top and / or Bottom Mounted Nozzles. The unique action created by the movement of the mixing elements produce intense but gentle intermingling of the materials of the mix in a mechanically fluidized bed. The unique mixing action of the FKM series mixers is accomplished by a horizontal shaft which revolves at a high rate of speed rapidly projecting and hurling the mix materials away from the vessel wall into free space, filling the entire vessel. The mixing action causes the materials to crisscross in the direction of the vessel walls and inversely back again, providing a high volume rate of material transfer. The mechanically fluidized bed of particles is the basis of it´s mixing efficiency and accuracy, including mixtures with diverse specific gravities as well as other problems such as liquid incorporation and heat transfer. Mixing elements are designed to force the product into appro- priate components of axial & radial motion. High-Speed Blending Choppers enhance mixing action by controlling particle size and trace ingredient dispersion, usually without the need for additional process steps.

5 sprayed liquids flowing in the opposite direction.
Chopper Action, sending fluidized particles upward, against sprayed liquids flowing in the opposite direction. Superb Liquids Dispersion into Powders, through high speed Choppers (Showing Top Injection Type. Bottom Liquids Injection also available)

6 Drying in The Littleford.
1.-High efficiency drying of Suspensions, pastes, and bulk materials. 2.-Fast drying cycles and discharge. 3.-Allows efficient drying of sensitive materials at low Temperatures. 4.-Complete dispersion of agglomerates, lumps and fiber bundles. 5.-Homogeneous mixing of dissimilar ingredients. 6.-Drying operations from liquid state to free-flowing powder in one vessel. 7.-Allows liquid addition during processing. 8.-Adapts itself to effective recovery of costly solvents. 9.-Eliminates need for additional processing equipment. The Key to this State-of-the Art drying technology is the unique, mechanically fluidized ploughshare action which agi- tates and individualize the solid parti- cles to be dried. The ploughshare action forces the product into a 3-dimensions motion that individualizes each particle, continuosly exposing tremendous surface area for drying The particles constantly contact one another, and the heated inte- rior walls of the jacketed vessel furthering the drying process Our dryers are also equipped with independently operated, high shear choppers, to reduce the particle size of the lumps or agglomerates, to expo- se undried materials and ensure thoroughly dried particle interior. Deagglomeration further shortens drying time. Heated Pulse Back Filter with Stack. Wet Product Condenser Littleford Dryer. Dry Product Recovery Tank. Vacuum Pump.

7 Stages of Drying: Why is the Littleford so efficient? Particle of
Time Paste Granule Powder M o I s t u r e L v l Constant Rate Period Falling Rate Diffusion Falling Rate: starts to retard drying Diffusion: Final Moisture loss Constant Rate. Surface & Subsurface Moisture Particle of Material Materials go through several physical stages during the drying process - Paste, Granule and Powder. Du- ring the early portion of the Paste Stage, the product is a thickening slurry which is readily put into turbu- lence by the action of the plows. The Dryer has been designed to achieve the critical Froude Nr. (The Point in which the plows force the batch into turbulence & thus maximize the heat transfer capability of the dryer. This attainment of the critical Froude Number enables fast, efficient transfer of the BTU´s required to satisfy the latent heat of vaporization, thus generating a much shorter drying cycle. Conventional dryers do not begin to achieve Littleford drying rates, even in this Liquid Stage of the drying curve where drying is most easily accomplished. As the slurry thickens at the end of the Paste Stage , (end of the constant rate period), the batch thickens to a mud-like consistency, which in conventional dryers causes the batch to ball or cake. This makes drying exceedingly difficult, since moisture (volatiles) must migrate from inside thrugh capillaries to the par- ticle surface before it can be flashed off. This point on the drying curve is where the limited drying rate of conventional dryers gets even worse, as internal par- ticle drying replaces efficient external drying. In the Granule Stage, Littleford Ploughshare Dryers, utilizing both the action of the turbulent plows and the high shear choppers, reduce the forming lumps to smaller granules, thus exposing large amounts of new surface for drying. Why is the Littleford so efficient? As the product moves from the Granule to the Powder Stage, continued use of the high shear choppers will break the dry- ing granules into fine Powder, allowing for possible elimination of further milling of the dried product.

8 Heat Transfer Graphics
The Littleford Dryer exhibits superior heat transfer coefficients, often two or three times higher than those of a ribbon or paddle dryers. As much as ten times higher than tumble or tray dryers. 49.2 41.0 32.8 24.6 16.4 8.2 U F a c t o r Froud Number % Moisture in Material Critical Plow Speed “Pasty” Pigment Mix “Crumbly” Littleford Ploughshare Dryer Paddle U Factor: BTU/Hr. - Sq.Ft. - F Degrees Heat Transfer Capability Heat Transfer Coefficients Comparative Example: Aqueous Pigment Paste, Highly Plastic

9 Advance Drying: The Chopper Advantages in Drying:
Fast, efficient drying without lump formation M O I S T U R E DRYING TIME PASTE GRANULE POWDER Internal Drying without Choppers External Drying with Choppers The action of the turbulent plows and the high shear choppers reduce the forming lumps to smaller granules, thus exposing large amounts of new surface area for drying.

10 How do we build them: Vacuum Systems Pulse Back Filters.
Standard or Sanitary Construction. TEFC or Explosion Proof Electric's. Full Vacuum or rated for several Internal Pressure Ratings. Single or Variable Speeds. Vacuum Systems Pulse Back Filters. Shell in Carbon Steel 304 SS or 316 SS #120 Grit finish. Liquid Dispersion Systems. Access ports with safety limit switches. Littleford Reinforced Shafts and Drives. Std.Packing, Air type & Mechanical Seals Jacket designed for high rates of thermal transference. 75 PSIG Mixing Plows designed to create a fluidized bed and excellent thermal transfer. High Speed Choppers, for granulation control, lump breaking & dispersion Contour discharge Valve, for No-Dead Spots

11 Manufacturing Options:
Vacuum System: Stack (s) Pulse Back Filter (s) Condenser, Receivers. Vacuum Pumps. Material: C.Steel, 304 S.S., 316 SS., Special. Interior: Std. #120 Grit or higher. Liquid Injection: Tower, Manifold. Top and / or Bottom Mountings. Vessel Construction: Atmospheric Std., Vacuum Rated, Pressure Rated, Sanitary Construction. FDA Ratings. Electric's: H.P., TEFC,Expl.Proof. Feeding Ports Drive Type. Sanitary or Welded Design RPM´s: 1 or 2 Speeds, Variable Speed. Hydraulic Coupling. Seals: Std. Packing, Positive Pressure Mechanical. Plows: Std.,Heat Transfer, Becker Jacket. Std. 75 PSI Other PSI Ratings Heating & Cooling Special Bases, Load Cells. Choppers: H.P., TEFC, Expl.Proof Blade Types Discharge Valve : Manual,Pneumatic. Ball type, Butterfly, Spherical & Slide Options. Control Panels: Manual, Automatic. RPM Control Batch Times, Amp,Power,Reports

12 Our regular sizes: Littleford Day Inc.
Working capacity depends on the process, and is normally between 50% and 70% of total capacity. TOTAL CAPACITY DIMENSIONS * Model Liters Gallons Cu.Ft A B C FKM-300-D ” ” 35” FKM-600-D ” ” 43” FKM-1200-D ” ” 43” FKM-1200-E ” ” 50” FKM-2000-D ” ” 51” FKM-2000-E ” ” 60” FKM-3000-D ” ” 60” FKM-4200-D ” ” 68” FKM-6000-D ” ” 80” FKM-8000-D ” ” 80” FKM D ” ” 80” FKM D ” ” 92” FKM D ” ” 96” FKM D ” ” 107” FKM D ” ” 110” A B C * Aprox. Vessel Dimensions Littleford Day Inc.

13 Optimizing Drying in the Littleford
Main reasons for drying operations: To facilitate handling and further processing. To permit satisfactory utilization of the final product. To reduce shipping costs. To increase the capacity of other equipment in the process. To preserve a product during storage and shipment. To enhance the value and usefulness of waste or various products. To make a product with physical characteristics more appealing to the customer. Reasons for drying under vacuum: Control temperature of temperature-sensitive products Recover solvents for re-use. Effective solvent removal under non-explosive conditions and control its safe handling. Capacity can be controlled, or varied, by processing small or large batch sizes to meet existing process requirements. As a general statement, all drying can be divided into distinct periods. In thecase of Vacuum Drying, it falls into (3) categories: Time known as the constant rate period, or that time the moisture is easily evaporated from the surface This occurs at a time when the material is substantially at the boiling point of the evaporating liquid under the absolute pressure conditions exixting in the dryer. That period known as the falling rate period when the material approaches the wall temperature of the dryer. As diffusion is taking place, the sensible heat of the material starts to approach the heating medium.

14 Successful Vacuum Drying Points
Optimizing Drying in the Littleford Successful Vacuum Drying Points Numerous test results have indicated that the most successful vacuum dryings are Achieved whenthe following conditions prevail: THE MATERIAL IS NOT SOLUBLE IN THE SOLVENT TO BE REMOVED. THESE TYPES OF PRODUCTS CAN BE FOUND MOSTLY IN PHARMACEUTICAL COMPANIES THAT ARE DOING MULTI-STAGE SOL- VENT PURIFICATIONS. THIS TYPE OF PRODUCT IS IDEAL FOR THE LITTLEFORD DRYER. IF THE MA- TERIAL IS SOLUBLE IN THE SOLVENT TO BE REMOVED, WE HAVE FOUND 20% TO 30% SOLVENT TO BE THE VERY MAXIMUM. GREATER CONCENTRATION CAUSED MASSIVE BUILD-UP AGAINST THE HEAT TRANSFER SURFACES AND VERY HIGH POWER DEMANDS (10 HP+ IN FM-130 PILOT UNIT). TWO TYPES OF DRYING IN THE LITTLEFORD PROCESS VESSELS: ATMOSPHERIC AND UNDER VACUUM Factors that control heat transfer: -Type of mixing tool -Speed of agitation -Jacket Area -Jacket Temperature -Boiling point of volatile component U = Q (A) (LmTD) Vessels that can maximize all factors for efficient drying: FM, FKM, VT and DVT types. Jacketing: -Cover Max. Area of shell. -Heat Shaft (optional) -Heat Heads (optional) -Circulation fluids in jacket at correct Reynolds number. -Connect all fluid flow from bottom-up. -Connect all steam top, out at bottom through trap. Must supply sufficient steam for process requirements.

15 Optimizing Drying In the Littleford 3rd. Page.
Explosion (overpressure) Protection: -All sealed units must be protected. -Units must be designed for pressure (not necessarily stamped or coded) Seals: -Packing for medium vacuum or atmospheric -Mechanical seals for high vacuum. Discharge Valves: Std.Contour, Ball, GEMCO Vacuum: -Vapor pressure controls B.P. (want to max-imize differential between jacket & product) -Millimiters Hg Abs. Vs in. Hg Ref. Vapor Port & line sizing: -Port = less than 3 Ft/Sec -Vapor line = less than 100 Ft/Sec. ** Expanded volume under vacuum. Vacuum Systems (Critical Proper Design): -Pump CFM pumping rate. -Condenser Ft2 and tube diameter. -Full or partial water recovery. IMPORTANT: Draw vacuum before running. N2 Flush: Low level moisture require it to lift vapor out of drier. Air drying VS Vacuum drying Optimizing Drying In the Littleford 3rd. Page. Plow Types: -Standard & Heat Transfer. Choppers: -Used to deagglomerate lumps. -Add small amount of heat to aid drying -Integral shafts are recommended. Pulse Back Filter: -Used to contain solids in dryer. -Use hot pulse air. -Must be heated above “dew point of volatile” -Sizing chart for most applications. -Seal seams of bags. -Use tight porosity bags with special coating. RPM´s: -Normal Speed is Std. – to maximize heat transfer -Keep same Froud # during scale-up -Some applications are at reduced speed due to Nature of product being dried, so as to keep motor Loads as low as possible. Drives: Single,Two-Sp.,Varaible or Hydraulic.

16 Drying Heat Sensitive Low Percentage Solids
The Littleford Day drying technology offers a highly efficient & economical means of drying heat sensitive low percentage Solids solutions. A considerable portion of the ingredients for the Food, Pharmaceutical, Nutraceutical and Biotechnical Industries is manufactured from the extraction or reaction of plant materials using solvents (water, alcohol, hexane, etc). This process leaves the processor with a product in the form of a liquid with a very low percent solids level (Hydrolized Vegetable Protein, St.John´s Wort, Enchinacea, and other Nutraceutical products). Processors have been searching for an economical way to dry these products. In the past, due to the stickiness of the Product during drying, the processor was forced to utilize drying methods such as frezze drying, spray drying, tray Dryers, etc., expensive methods which did not rely on mechanical agitation of the product through the high viscosity “Power Phase”. Typical Littleford vacuum drying process: 1.- Product is placed in the Littleford Ploughshare Vacuum Dryer. Agitation Is initiated (plow & choppers (optional) followed by heating media (hot water, Steam hot oil) on the vessel jacket to raise the temperature of the product in The dryer to the predetermined drying temperature. 2.- With the vessel under vacuum, a fine spray of the low solids solution is Atomized into the heated bed of dried material. The rate of spray is matched To the rate of vapor evolution in order to mantain the bed of materials as a Dry medium. 3.- After sufficient material has been dried to raise the batch size to a 70% Fill, the product is cooled (via cooling media on the vessel jacket) to the Required temperature for subsequent processing (other ingredients added, Product granulated, etc.) or discharge. Dryer. Wet Product Condenser Recovery Tank. Vacuum Pump. Liquid Injection

17 Advantages of the advanced Littleford process:
1.- Controlled drying through effective/optimum heat transfer 2.- Improved Drying rates. 3.- Increased efficiencies of drying. 4.- Efficient single unit processing of the entire process The Littleford equipment used to accomplish this Advanced processing is the Littleford Ploughshare Vaccum Dryer, which combines the operational fe- Atures of liquid injection, vacuum operation and Effective heat transfer (heating or cooling) to dry in a single processing unit. It operates according to the proven “fluidized bed” mixing principle, Whereby the materials being processed are man- Tained by the plow shaped mixing elements in a Mechanically fluidized “suspeded” state. This Permits liquid and solid media to achieve intimate Individualized, rapid contact with each other and The heat transfer surfaces. In addition, the Littleford Ploughshare Vacuum Dryer may Be equipped with independently operated, high shear “chopper” devices to treduce the particle size of any Lumps or agglomerates, exposing undried materials Thereby ensuring thoroughly dried particle interiors. This Deagglomeration further shortens the drying time required. It is specifically dengineered to maximize heat transfer, Yields coefficients that are many times higher than those Of traditional dryers. This advanced heat transfer techno- Logy generates rapid drying in a single process vessel. It can be enhanced with an optional Pulse Back Filter to Effectively handle the vapor steam created during steam Stripping and drying. The Littleford process enables the processor to produce an excellent, dried product with solvent levels well below the limits set by the FDA. The Littleford Ploughshare Vacuum Dryer is designed and constructed according to “GMP” and to meet or exceed FDA, 3A, USDA, compliance As specified by the customer. This proven Littleford technology has been applied to numerous complex and difficult applications in the Food, Pharmaceutical, Nutraceutical And Biotechnical Industries. Littleford Ploughshare Vacuum Dryers can be purchased in a variety of sizes to meet most production require- Ments. Littleford can interface its system controls with existing equipment or supply fully automated process control systems

18 Typical Applications Q-R-S-T-U-V-W-X-Y-Z H-I-J-K-L M-N-O-P A-B-C
Paint Sludge Slurry Para Toluene Sulfonate Paraformaldehyde Peat Moss (Vermiculite Mix) Penicillin Powder Pesticides Pharmaceuticals (Intermediate) Photographic Process Sludge Pigments Plastic Resin Beads Polyethilens Polymers Polyvinil Alcohol Potassium Boro Fluoride & Phenate Protein Modifications Psyllium Seed Q-R-S-T-U-V-W-X-Y-Z Refracting Powders Resin Beads Selenium Metal Filter Cakes Sodium: Methylate, Phenate, Stearates Specialty Chemicals Starch Powder Sulfonated Polystyrene Temperature Sensitive Enzymes Tugsten Carbide Slurry Toxic Sludges Vitamin Mix Wet Friction Lining Wheat: Bran, Farina & Germ Zinc Diacrylate A-B-C Acetoquanamine Acetyl Salicilic Acid Acrylic Powder Agricultural Herbicides Aluminum Hidroxide Slurry Animal Byproducts Animal Feed Products Animal Waste for Fertilizers Barium Stearate Boric Acid Solution Brewer´s Yeast Cadmium Oxide Calcium Stearate Carbon Black Carbon Fibers Carboxi Methyl Cellulose Carrageenan Catalyst Cellulose Cetylpyridinium Chloride Chmical Dye Intermediate Chocolate Citric Acid Coal Ash Slurry Cocoa (Dutching) Cocoa (Processing) Coffee (Decaffeinating) D-E-F-G Dental Adhesive Dextrose Dye Intermediates Enzimes (Temp.Sensitive) Ethyl Cellulose Fillers Fish Meal Flammable Sludges Flour (Toasting) Friction Material Graphite Filter Cake H-I-J-K-L Herbicides Inks Inorganic Filler Powders Iron Oxide Filter Cake Lead Phthalates/Stearates Lecithin Oil Extract Liquid Fungicides Lithium Fluorite M-N-O-P Magnesium Stearates Metal Binders & Reclaim Methyl Cellulose Modifies Protein Powdre Molibdenum Disulfide

19 Rental Programs In addition to our Process Development & Testing Programs, our Rental Program offers a unique opportunity to test our processing equipment in your own Plant. Batch Mixing / Processing Ploughshare Units, both for atmospheric / vacuum and Pressure Ops. : From Table-Top 5 & 20 Lts units to Pilot 130 Lts. Machines Larger sizes are available. W-10 High - Intensity vertical mixer, for PVC Compounding and /or other applications req- uiring High-Shear Op. Ten Liters Capacity. Daymax # Dispersers, for high quality dispersions of solids into liquids, such as plastisol, varnish, paint, and other applications. FA-3.5 Mixer, Nauta-Type, for special mixing / drying requirements Gallons Working Capacity. A portion of the rental cost, under this program, will be applied to the purchase of any related Littleford Day Equipment.

20 Service & Spare Parts Exclusive Dept. for customer assistance.
Laboratory for formulations & optimization. Specialized Field Service Engineers. Stock of common required parts. Top American Mfrd. Parts: SKF, Falk, Chesterton, etc.,etc. Assistance in Spanish, if required. The Best Service Department. Direct Sales Force. No Reps. Own Manufacturing Facilities.

21 Process Development & Testing
Main Office: Florence, Ky. Ph.- (606) Fax: Latin America: Mexico Cy.Ph.- (52-5) Fax: Minutes away from Greater Cincinnati Airport, Our Lab. Center is fully equipped with all the required machinery for product development: Mixers, Dryers, Reactors, Granulators, Intensive Mixers-Coolers and support equipment such as filtering and vacuum drying systems. Cosmetics Detergents & Soaps Foundry Additives Pharmaceutical Ceramics Fertilizers/Seeds Rubber Mortar Mixes Brake Linings Powdered Metals Herbicides Flame Retardant Chemicals Pigments & Color Flushing BMC & SMC Plastics. Color Concentrates PVC Compounding Coatings Plastisols Adhesives & Caulks Inks & Varnish ChemicalReactions & Drying Cellulose Reactions Spices Chocolate processing Gelatin & Powdered drinks Bakery Mixes Instantanization Industrial Road (1 Mi) Donaldson Rd. Turfway Rd. U.S. 42 Exit 180 Florence Union Greater Cincinnati Airport I-275 I-75 To Lexington To Cincinnati 7451 Empire Drive Florence, KY (1/2 Mi) Technical Center Main Equipment: FM-130 Mixer/Processor Ploughshare DVT-130 Polyphase Reactor KM-150 Continuous Mixer/Processor M-5 Lab. Mixer & Dryer W-180/K-300 PVC Compounder W-10 High Intensity Mixer Daymax 10 Pastes Disperser Daymax 100 Pastes Disperser Mixtruder Sigma Double-Arm Mixer Mogul Tangential Sigma Mixer Cincinnatus Overlapping Sigma Mixer FA-10 Nauta Processor Bring Us Your Toughest Mixing, Drying & Reacting Problems.


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