Industry Blog

30
Nov 11

Lump Breaker in Action

The size reduction of agglomerated bulk material is imperative to the success of various processes such as milling and sieving. The SureBreak disperses large particles reducing the strain on downstream process equipment, enabling efficient operation without overloading. Moreover, pre-breaking is ideal for size reduction into machines with inlets too small to accept material in large pieces.

Agglomerated material is fed into the SureBreak and is forced between the breaker arms where it is crushed into smaller particles. By selection of the number and size of breakers, it is possible to select a suitable finished product. The SureBreak can be used for a variety of applications across the pharmaceutical, food, chemical and associated industries.

The above trial shows the Lump Breaker crushing large crispbreads to a smaller particle size.  This process enables the the pieces to be small enough to fit into a cone mill or other downstream process.

We are able to offer free trials on your product at our UK Test Facility. If you are interested in testing your material on our size reduction systems, simply contact us.

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30
Nov 11

Uni-Mill Cone Mill Case Study

Introduction

A customer was looking to replace their existing cone mill for a newer, updated design. The customer required the cone mill for a dry milling application in the pharmaceutical industry.

One concern the customer had was the build up of heat during dry milling. The product was extremely heat sensitive and required careful attention otherwise the screen would blind. To prevent heat building up too much the customer was running their existing machine for 10 minutes, then leaving it to cool for another 10 minutes, before running the machine again. This was causing production to take twice as long as necessary.

 

Our Solution

Hanningfield’s flexibility enabled us to look at the problem in detail and to design an appropriate solution, rather than merely offering ‘off-the-shelf’ technology.

The existing machine used gears to drive the gearbox. Hanningfield suggested the use of a belt to perform the same task, resulting in a significant heat reduction.

Alongside this, the customer realised the additional benefit of a reduction in noise, as the belt offered a quieter alternative to traditional methods.

The mill was also fitted with a screen temperature probe assembly. This monitored the screen temperature and would automatically shut down the machine if a certain temperature was reached. This prevented the need for constant operator supervision.

 

Results and Conclusions

Overall, the machine achieved the customer’s original goal of utilising an updated, more modern mill.

However, the benefit ran much deeper than this through the use of a belt to provide a cooler operation. In fact, the heat reduction was sufficient enough to enable the machine to be run continuously, without the need for downtime.

In an age where continuous and lean manufacturing is promoted, the customer was able to implement an improvement which would eliminate downtime and consequently ensure a better, more efficient process.

Due to this, the improvement offered the customer excellent return-on-investment and will ultimately pay for itself through increased production.

 

Key Facts

- Low Heat: Ideally, a machine is used to process a material, not to change its core characteristics. The low heat generated by the Hanningfield ‘Uni-Mill’ means that the milled product is not altered by the temperature created during grinding. Moreover, many hygroscopic products do not fare well under high temperature conditions. By keeping the temperature optimised, the mill does not negatively affect the product.

- Low Dust: Minimal dust generation is important as excess powder escaping to the atmosphere can be harmful for operators and potentially hazardous to the operating environment. The ‘Uni-Mill’ cone mill produces comparatively little dust compared with many alternative milling processes. Moreover, the Uni-Mill can be integrated with various other pieces of equipment to create a totally-contained, dust-free milling process.

- Low Noise: Minimising noise is desirable to help comply with Health and Safety requirements for maintaining a safe working process environment.

 

For more information on the Uni-Mill cone mill, please click here.

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28
Mar 11

Raw Material Milling

The milling of raw materials to a finer, more consistent particle size is commonplace in many industries, namely pharmaceuticals, food, chemicals and cosmetics.

The Hanningfield Uni-Mill cone mill is available in a variety of sizes to handle different throughputs. Throughput will depend on material characteristics, but can reach up to 7,200 kgs/hr (16,000 lbs/hr). Smaller models can handle various throughputs, and a lab size mill is available for requirements up to 200kgs/hr.  Please just contact us for more information.

The Uni-Mill is designed and manufactured in the United Kingdom by Hanningfield.

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Posted in Cone Mill, Milling, Powder Processing, Size Reduction, Uni Mill | No Comments »
4
Mar 11

Lump Breaker

Features

• Stainless steel construction
• Low maintenance, easy-clean design
• Compact Size
• Low mounting space
• External outbound bearings
• ATEX Versions available

Technical Specification

• Throughput: Up to 10,000 kgs/hr
• Inlet dimensions: 450mm x 550mm
• Motor Power: 2.2kW

Colin Ellis

Product Profile

The size reduction of agglomerated bulk material is imperative to the success of various processes such as milling and sieving. The SureBreak disperses large particles reducing the strain on downstream process equipment, enabling efficient operation without overloading. Moreover, pre-breaking is ideal for size reduction into machines with inlets too small to accept material in large pieces.

The SureBreak lumpbreaker features either single or double shafts with rotating breaker-arms. The breaker arms cross mesh with stationary breaker bars mounted on the inside of the lump breaker machine.

The SureBreak lump breaker is a low speed machine that reduces the product by a cutting and sheering action. Furthermore, no grinding takes place during the size reduction process, resulting in no heat generation, less noise and no metal-to-metal contact.

Agglomerated material is fed into the SureBreak and is forced between the breaker arms where it is crushed into smaller particles. By selection of the number and size of breakers, it is possible to select a suitable finished product. The SureBreak can be used for a variety of applications across the pharmaceutical, food, chemical and associated industries.

The lump breaker is designed and manufactured by Hanningfield in the United Kingdom.

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13
Jan 11

Technical Article: Understanding ATEX Milling

By Colin Ellis (Managing Director, Hanningfield)

Introduction to ATEX

Past legislation to control explosive atmospheres has only been concerned with electrical equipment. The current ATEX directives now include hazards from mechanical sources, such as mills. A seized bearing or mechanical failure causing excessive heat generation is as likely a cause of explosion as an electrical fault and is now considered of equal importance in the design and use of size reduction equipment for powder processing.

ATEX Standards
There are currently two European directives in existence, 94/9/EC which is principally for manufacturers and another for operators of the equipment 99/92/EC. 94/9 EC is implemented in the UK by the Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres Regulations 1996 (EPS Regulations). 99/92/EC is implemented in the UK by the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).

Both EU directives have been in place for several years, 94/9/EC since 1st July 2003 and the provisions of 99/92/EC extended to 1st July 2006.

Complying with ATEX
To comply with these standards a number of precautions must be taken to eliminate any risk potential. The first step is to carry out a risk analysis (Ignition Hazard Assessment) on the product to be milled and the environment in which the size reduction process will take place. This assessment will determine type of hazardous zoning inside and outside the mill and should be carried out by the user of the equipment.

Using the information provided, the mill supplier can then design the equipment to meet the appropriate ATEX Directive measures. The mill supplier is also responsible to advise the user of any precautions necessary to operate the mill safely.

ATEX Categorisation
In addition to the consideration of mechanical machine features, further categorisation is divided between gas and dust risks. The levels of risk fall into various zones; 0, 1 or 2 for gas, 20, 21 and 22 for dust. There are also individual equipment categories; 1, 2 and 3 (see table).

Zone (Gas) Zone (Dust) Zone
Definition		 Equipment Category Protection

Method
0 20 Explosive atmosphere is present continuously, for long periods or frequently. 1 Equipment must be safe under normal operation, expected and rare malfunction.
1 21 Explosive atmosphere is likely to occur occasionally under normal operation. 2 Equipment must be safe under normal operation, expected malfunction.
2 22 Explosive atmosphere may occur under abnormal operation and only persists for a short period. 3 Equipment must be safe under normal operation.

Source: RS Components

To comply with each level of risk various accessories may be fitted to the machine such as temperature sensors, nitrogen purging systems, earth-bonding and anti-static castors. ATEX rated electrical equipment and accessories are also used including motors, safety switches and control panels.

Equipment Location
It is important to ensure that when positioning equipment that either contains an explosive atmosphere, or is situated in an ATEX zoned environment that the location is matched with the equipment in use. If the equipment is situated in an ATEX zoned area then the external features of the mill must comply with the ATEX provisions according to the zone. Special care should be taken relating to the effect on the surrounding area and also affects resulting from the surrounding area.

Manufacturer’s Responsibilities
The mill manufacturer has a responsibility to the customer to provide correctly designed equipment and the user or purchaser has a legal right to expect an acceptable level of safety from the equipment supplier. It is therefore or paramount importance to ensure the user has adequate information on the limitations of use and operating parameters. Adequate instructions of the limitations of use and operation must be supplied along with training where required to ensure equipment is use safely and as intended.

The ATEX Compliant Hanningfield Mill
With many years experience of designing and supplying explosion category milling equipment, the Hanningfield UNI-MILL provides the ideal solution to meet ATEX legislation directives. Special features such as continuous earth design, temperature monitoring and nitrogen purging ensure appropriate compliance measures are in place for every machine supplied to meet the level of hazard specified.

Although ATEX legislation appears to be quite complex, with proper consultation between user and supplier a safe system that meets the requirements of ATEX can be fully complied with.

For more information on the Hanningfield Uni-Mill, click here.

Or to learn how to contact Technical Sales, click here.

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Posted in Cone Mill, Conical Mill, Conical Mills, Conical Screen Mills, Dust, Dust Control, Milling, Size Reduction, Technical Article, Uni Mill | No Comments »
21
Dec 10

Food Cone Mill

Size reduction is a major part of food processing. Most ingredients or products undergo some form of powderisation, deagglomeration or delumping before they become a finished product.

In cone milling, the material is fed through the in-feed chute, using either gravity feed (manually or automatically operated) or by using a vacuum. The material is forced downwards towards the rotating impeller (see picture below), where the centrifugal force pushes the material through the screen, in the required particle size and shape.

Above: Food Cone Mill Grinding Red Peppercorns
Above: Food Cone Mill Grinding Red Peppercorns

Once the material has passed through the cone mill screen, it falls can either fall into a receptacle ready for storage, or automatically flow to a downstream process, offering excellent processing efficiency.

The cone mill can be used for a wide variety of applications in food processing, such as powder or breadcrumb manufacturing, product reclaim, the deagglomeration of food (such as raisins and other dried fruit), the delumping of powders and the size reduction of herbs, spices, flakes (see picture below).

Above: Finished Product of Milled Red Peppercorns
Above: Finished Product of Milled Red Peppercorns

A cone mill is an extremely common and effective method of size reduction in food processing, as it is capable of achieving a high throughput and consistent particle size. The Hanningfield Uni-Mill cone mill also generates low levels of noise and dust, offering significant operating advantages. Importantly, the Uni-Mill also offers an ‘easy-clean’ design, making strip-down and cleaning between processes simple. Manufactured from stainless steel, the Uni-Mill cone mill (pictured below) is a high-performance, low maintenance and extremely hygienic system for size reduction in food processing.

Food Cone Mill
Above: The Hanningfield ‘Uni-Mill’ Food Cone Mill

For more information on the Hanningfield Uni-Mill cone mill click here. Alternatively, to contact a member of our technical sales about using the cone mill for food processing, simply click here.

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20
Dec 10

Cone Mill

A cone mill is an extremely effective machine for size reduction. The advantages of a cone mill over other forms of size reduction mean it is widely used in the pharmaceutical, food, chemical, cosmetic and associated industries.

Above: Cone Mill Screens
Above: The Hanningfield ‘Uni-Mill’ Cone Mill

So-called because of the screen shape (pictured below), a cone mill can offer great adaptability in terms of throughput, particle size, particle shape and many other factors, simply by changing the type of screen or impeller; for example, a screen with a smaller hole size will produce a smaller particle size.

Above: Cone Mill Screens
Above: Cone Mill Screens

Material is fed into the cone mill through an in-feed chute. This can either be charged into the mill using a vacuum or gravity feed. The material passes to a rotating impeller which forces the material through the holes in the screen. Once the material has passed through the screen, the finished product falls from the bottom of the mill to a receptacle beneath.

The cone mill can be used for a wide variety of applications.  In pharmaceuticals, they are often used for wet/dry granulation, tablet reclaim etc., in chemicals the are often used for deagglomeration, in cosmetics it can be used for fine grinding and in food it can be used for deagglomeration, product reclaim and general size reduction.  For example, seeds or nuts (such as almonds, pictured below) can be ground to a smaller particle or even a powdered state.

Above: Cone Mill Screens
Above: Almonds which have been ground in the ‘Uni-Mill’ Cone Mill

For more information on the Hanningfield ‘Uni-Mill’ cone mill click here.  Alternatively, to contact a member of our technical sales for assistance, simply click here.

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7
Dec 10

Conical Mill

A conical mill is a machine for reducing the particle size of material, to create a consistent and uniform finished product.  The conical mill benefits from low noise, minimal heat, reduced dust, higher throughput and a more uniform finished particle size.

Material is fed into the conical mill via the in-feed chute, this can either be via gravity feed or by vacuum.  Once the material has passed through the in-feed chute, it the reaches a rotating impeller which forces the material through the holes in the screen.

With a conical mill it is possible to alter the particle size, particle shape and other characteristics, simply by changing the screen.  For example, the hole size will determine the particle size, so a larger hole will produce a larger particle.  Once the material has passed through the screen, the finished product exits through the milling chamber into a receptacle beneath.

Hanningfield offer the conical mill in a range of different sizes.  From table-top sized mills, to full-scale production models, a conical mill can be used to satisfy a wide range of requirements, most notably in the pharmaceutical, food, chemical and cosmetic industries.

Typical applications for a conical mill include:

  • Reclaiming broken tablets, biscuits or other material
  • Sizing wet granulated particles before drying
  • Sizing dry granulated particles before tabletting
  • Deagglomerating dried fruits or other clumped material

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For more information on the Hanningfield conical mill, please click here.

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30
Jun 10

Uni Mill: Conical Screen Mills

The Uni-Mill conical screen mill draws upon Hanningfield’s wealth of experience in size reduction for the process industries.

Conical screen or ‘cone-milling’ is ideal for achieving a fine, uniform particle size.  By combining high throughput and high efficiency, the low energy Uni-Mill is perfect for the pharmaceutical, food, chemical and consumer goods industries.

The Uni-Mill is designed and manufactured by Hanningfield Process Systems at our UK Headquarters.

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11
Jun 10

Powder Milling Equipment

The milling of powder to a fine and consistent particle size is a vital aspect of processing in the pharmaceutical, food and allied industries.

The Hanningfield Uni-Mill enables an accurate and repeatable particle size to be achieved, with a focus on hygiene and productivity.

For more information of Hanningfield’s powder milling equipment, please click here.

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