Readco Tip of the Week
Many times, the Continuous Processor is referred to as an Extruder. From the outside, they do have similar shapes, but they do very different things.
The Continuous Processor is a low pressure mixer. Typically 125 psi pressure at the discharge end.
Extruders are not good mixers, they are built to generate high pressures, and thus have much less area to combine materials inside the barrel, and have a much higher energy consumption to mix the product.
The Continuous Processor can accommodate very high rates of input materials, and can take light fluffy ingredients, whereas an extruder cannot.
The machinery cost to mix in a Processor, is usually much less than an extruder, because the size and design to produce high pressure, is more expensive. Typically 25 to 40 % higher cost than a Processor.
A Processor can be sold as a pre conditioner to an extruder, to increase the thru put of the extruder up to 25%.
So, if mixing is your major need, then you do not need an extruder… you need a Continuous Processor!
What are the advantages of continuous mixing?
Continuous mixing can eliminate batch to batch variations and environmental concerns. It can also allow you to reduce your cycle times! A Readco processor is a versatile and flexible machine, which makes it a natural for pilot labs and today’s evolving manufacturing marketplace. Considering going from batch to continuous? Below is a batch versus continuous comparison check sheet. Would there be advantages for your process to go continuous?
| CONCERN | BATCH | CONTINUOUS |
| Consistency of Product Quality | Batch to Batch Variations | Consistent Controls By Feeders & Pumps |
| Floor Space | Usually Large Area | Small Footprint |
| Total Mixing Time | Very Long 10 Minutes to Several Hours | Very Short Less than 1 Minute |
| Clean Up Labor | Intensive & Cumbersome | Very Quick, Clean In Place |
| Work In Process | Required | On Demand Production |
| Multi Stage Processes | Usually Single Step | Can Accommodate Many Processes |
| Utility Costs | Dependent on Motor Size & Mixing Time | Smaller Motor, Shorter Mixing Time |
| Environmental Issues | Usually Not Contained | Enclosed, Contained, & Controlled. No Cleanup Issues |
| Scrap Potential | Sizable Amount of Scrap | Small Amount of Scrap at Startup & Shut Down |
United Air Specialists
New Release
New White Paper From UAS Details Fume Collection Solutions for Hexavalent Chromium Exposure
CINCINNATI, OH - A new white paper from the United Air Specialists (UAS) provides specific guidance on how to comply with OSHA specifications on hexavalent chromium and minimize harmful exposure through air filtration.
Hexavalent chromium (CrVI) compounds are used as corrosion inhibitors and present an occupational hazard to workers that weld, cut, torch cut or grind chromium-containing metals such as stainless steel. Exposure to hexavalent chromium through inhalation or touch can pose significant health risks to workers, including lung cancer, skin and membrane ulcerations, allergies and skin irritation.
Welding environments can vary in a number of ways, including the welding process in use, the amount of hexavalent chromium fumes generated and the welding location. In this paper, UAS experts explain why a source capture system combined with a cartridge collector is the only viable way to deal with stainless weld fumes in each of these scenarios.
About United Air Specialists
For more than 40 years, United Air Specialists, Inc., has been an industry leader in designing and manufacturing technologically innovative, high-performance custom air filtration equipment for a wide range of industrial applications. United Air Specialists, Inc., is a CLARCOR Company. For more information, at about UAS equipment, call 1-800-252-4647, or visit www.uasinc.com.