Granular pigment distribution systems rely on piston vibrators for Optim
Since 1986, Interstate Industrial Technology (Industec) has been a leading manufacturer of pigment dosing equipment for the concrete manufacturing industry. These complex systems have been supplied to customers in North America, Europe, Asia and Australia. The company’s systems and controls have also gained acceptance in the printing, agricultural and chemical industries.
But concrete producers are Industec’s main customer, especially for its EZ Blend-branded granular pigment delivery system, according to Scott Dawson, production manager for Industec. “Our distribution systems are used to make a wide variety of concrete products containing color pigments, from landscaping pavers and other architectural materials that use colored or stained concrete,” he says, adding that the systems are designed to handle 50,000 to 1.5 million pounds or more of volume per year.
The EZ Blend Pigment Granule Delivery System (GDS) has been a backbone of the company. The GDS can be designed to dose pigments from up to eight feed stations to accurately dose hundreds of unique mixed pigment formulas. Efficient movement of pigment material out of feed stations and onto weighing vessels requires the use of VMSAC, VMS, and SA-EP pneumatic piston vibrators from Cleveland Vibratory Co.
According to Dawson, Industec has purchased more than 500 vibrators over the past 10 years from St. Louis-based Flori Equipment Co., distributor of Cleveland Vibrator. Industec has been purchasing various HVAC products from Flori since 1990.
Custom-designed EZ Blend systems include the 1200, 1300 and 1350 VMSAC HVAC, 1125 VMS and 1/2 SA-EP models. HVAC vibrators range from 1 ¼-in. piston diameter to 4 inches. diameter, depending on how each system is configured to a customer’s specifications.
Industec pioneered the use of dosing by weight in the North American pigment industry in 1986. Today, its pellet and liquid dispensing systems are custom made for each customer and shipped fully assembled. , designed to be easily installed and put into service by the customer. . The Dupo, Illinois-based company offers field support for final hookup and commissioning if needed.
Versatile vibrators accelerate material flow
“The EZ Blend system combines fast fill times with precise results,” Dawson notes. “Most of the material is added in rapid filling. As the fill target is approached, the fill rate is reduced so that the last small amount of pigment is added very precisely. The operator can load up to four mix formulas for each mixer served by the GDS.
This “three-speed fill” approach means the HVAC vibrators work continuously to “rock the feeders back and forth” and help move the pigment material into the weighing vessel, according to Dawson. “Each feed tray has a vibrator, and depending on the color load, the vibrators run an average of three minutes intermittently in a 10-minute batch cycle,” he explains. “So there are downtime when the vibrators are not working, but it is essential that the pigment material is transported accurately and the CVC vibrators help regulate this material flow. “
Industec technicians determine which HVAC vibrators are installed on custom-designed EZ Blend systems for optimal material flow. In a typical four bag system, the two interior feeders will use a 2 inch. pneumatic piston vibrator, while the two outer feeders will employ a 3 inch vibrator. pneumatic piston vibrator. If a fifth power station is designed, then a 3½ or 4 inch. a pneumatic piston vibrator is recommended.
Different models for different uses
Customers also have the choice of models of HVAC vibrators, again depending on the nature of the job, plant conditions and the volume of pigmented material processed. The VMSAC Vibra-Might unit features pneumatic piston damping to prevent metal-to-metal contact and reduce noise. The Vibra-Might VMS model uses air-to-metal piston impact for maximum force output. Finally, the SA-EP spring unit features high vibration frequencies and adaptable mounting heads.
“The advantage of using the Cleveland Vibratory models is that they are designed to start in any position, while the other vibrators we’ve tried have to lean in one direction to start,” Dawson said. “We looked at some electromagnetic vibrators from other companies, but ultimately chose to install HVAC’s air piston models. We thought it was an efficient and economical way to do it.
Another benefit of HVAC vibrators, according to Dawson, is the inclusion of threaded and tapped exhaust ports. This allows the orifice protector / muffler to be installed which helps prevent impurities from entering the vibrator through the exhaust port. It also helps reduce some of the noise coming from the vibrator when it vibrates.
Other features of EZ Blend GDS make it ideal for concrete builders. The dispenser control system integrates an industrial programmable logic controller and a touch screen. The pre-assembled and pre-wired control panel is designed to withstand harsh industrial environments.
Pressure relief enables rapid emptying of the dosing chamber to mixers at distances of up to 150 linear feet and at a height of 30 feet. The EZ Mix also has a very low profile because the height, including the Supersack racks of pigment, is less than 14 feet.
Dawson says there is an upward trend in the home improvement market, which is indirectly linked to the resumption of new building construction in the residential and commercial markets. This, in turn, creates more opportunities to market Industec EZ Blend pellet distribution systems, all of which contain vibrators from Cleveland Vibratory Co.
The advantages of VMSAC air cushion piston vibrator and VMS impact piston vibrator include:
• One piece ductile iron housing, hand finished bore and springless design ensure long life.
• VMSAC: Air cushion metal-to-metal impact prevention and exhaust muffler reduce noise levels while pneumatic power enables hazardous area operation.
• VMS: The use of an exhaust silencer reduces noise levels while the compressed air supply allows operation in hazardous areas.
• Dual diameter piston allows mounting at any angle on bins, chutes, pipes and hoppers handling material loads from 200 lbs to over 100 tonnes. Industrial vibrators come with mounting clips and gasket for quick installation
The advantages of the SA-EP spring activated piston pneumatic vibrator include:
• Steel housing and exhaust port protection ensure long continuous service life.
• Muffler offers reduced noise levels and pneumatic power allows operation in hazardous areas.
• Spring activation of the piston allows mounting at any angle on a variety of brackets.
The Cleveland Vibrator Co. (Cleveland, OH) manufactures pneumatic piston, rotary electric, electromagnetic, turbine and ball vibrators, as well as a wide variety of feeders, vibrating screens, ultrasonic screens, vibrating conveyors and of vibrating tables used for light, medium and heavy industrial applications. For more information call 800-221-3298 or visit www.clevelandvibrator.com.
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