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CONE MILLS

LOW ENERGY SIZEREDUCTION FOR THEPHARMACEUTICAL,FOOD AND CHEMICALINDUSTRIES

kemutecSpecialists in Powder Processing Technology

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THE CONE MILLING CONCEPT AND ITS BENEFITS

Cone milling is a low energy size reduction concept

ideal for fatty, heat sensitive, sticky, moist or otherwise

difficult to grind products. It alleviates the noise, dust

and heat problems associated with traditional milling

techniques at a stroke.

A gentle grinding action, capable of control within fine

limits, maintains a close particle size distribution with

minimal fines generation.

Because the residence time required to process

product is very short, heat generation is negligible,

and build up is drastically reduced - even for moist or

sticky products.

The inherent benefits of cone milling are rapidly

becoming universally accepted. Kemutec engineers

have developed a range of machines to meet the ever-

growing demands of today’s

pharmaceutical, chemical and

food industries.

Material to be processed is gravity fed into the milling

chamber. The low velocity Grinding Rotor forces the

feedstock into a vortex flow path. The individual

particles of unground product are centrifugally

thrown out to the wall of the conical grinding

chamber against which they then rise in a spiralling

path. The action of the Rotor against the grinding

chamber wall imparts high shear on the product. A

very large percentage of product is reduced to below

the cone aperture size on initial impact. This is

instantaneously discharged into the mill discharge

chute. The chute is designed to give maximum free

space to exiting material, thus preventing the

possibility of build up.

A small percentage of larger unground particles

continue their path up the conical wall within the

product vortex undergoing further size reduction in

the process. The very largest may eventually reach

the top of the vortex where they re-enter the in-feed

streamto repeat the cycle.

cone mills

User benefitsHigh efficiency - Virtually all the energy

input is utilised in the size reduction

process.

Gentle grinding action - Permits

uniform size distribution, resulting in the

minimum of fines.

Low heat generation - essential when

milling fatty, sticky or heat sensitive products.

Low dust levels - No need for air filtration. Keeps

installation costs to a minimum.

Low noise - No costly acoustic protection. Mobile

units can be used in any location.

Flexibility - Free standing mobile units, standard

models as part of process systems and special,

bespoke units as an integral part of other capital

equipment.kemutecSpecialists in Powder Processing Technology

Ultra-Hygienic Designs

Cleanability was a high priority during the design ofthe new mills. Generous radii, large accessible gapsbetween components, mostly tubular stainless steelsupport frames and cast mounting blocks for fittings,all contribute to maximum hygiene.

All models can be cleaned with high pressure hoses;electric interlocks are housed in enclosures orbeneath the covers they protect, and access coversand motor shrouds are sealed with easy to remove‘U’ section silicone seals.

Constructed of 316 grade stainless steel,the new KEK Cone Mills are availablein a variety of finishes includingbead blast, crack andcrevice freewelds and mirrorpolished finish.

The bearing housings - criticalcomponents in any mill - aresecond to none. All bearinghousings are bench run-in beforefinal assembly into the mill, andare designed to run under fullysubmersed conditions. Provision isincluded for air-purging whererequired.

High Integrity Grinding Media

Each cone is formed from a pre-punched development, totallyeliminating all part or blindapertures. Complex fixingflanges and cone caps havebeen eliminated, ensuring thatcones are easy to remove, handle, clean andreplace. The rotors are one piece components,bead blast or mirror polish finished as required.

Innovative Cone Retention

Changing cones could not be easier. Captive swingbolts release the hinged milling chamber whichswings down complete with the cone - which cansimply be lifted out and replaced.

Novel Rotor Adjustment

Much of the appeal of cone mills is the flexibility of thegrinding media - which can be changed easily, quicklyand safely, with the minimum of disruption toproduction. Another patented innovation is the easilyadjusted rotor/cone clearance. The retaining nut issimply loosened and the rotor turned to anotherposition. The rotor drive dogs pick up on a series of

alternative castellations on the rotor, all of whichare machined to a different depth. Theretaining nut thread is orientated to ensure that

it cannot come loose during operation.

Engineering At Its Best

There are nooperations which require three hands; there’s

no guess work as to how tightly gaskets should becompressed; and swing bolts may be allowed toswing without fear that they’ll mark highly polishedsurfaces.

We’ve paid all the attention to safety and easytransportation you would expect from Kemutec. Theinnovative features and quality design found in thisnew generation of KEK Cone Mills will set them apartfrom the competition for years to come.

THE RANGE

Kek manufactures a wide range of Cone Mills from

the worktop mounted ‘75’ Model through to the ‘680’

capable of a process rate up to 10 tph. Although we

offer a comprehensive range of standard design

Top driven belt drive

• The standard for ‘hopper feed’

installations

• Offers the option of speed

change via pulley sets

• The most versatile arrangement

machines, each model in the range is capable of

being customised to suit each customers’ individual

requirements.

The current range

Our extensive applications experience over the

years, during which we have responded to the ever

changing needs of our customers, has resulted in a

Customizing options - Drives

comprehensive range of drive options from

which we select the best for your requirements.

Model Cone Use Top Top Under Under In-line Grinding eludomnevird nevirdnevirdnevirdaiD

direct belt direct belt onlydrive drive drive drive

75 75mm Lab •120 120mm Lab/pilot •170 170mm Pilot/production • • • • • •220 220mm Pilot/production • • • • • •340 340mm Production • • • • • •540 540mm Production • • • • • •680 680mm Production • • • • • •

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cone mills

kemutecSpecialists in Powder Processing Technology

In-line under-driven belt drive

• No drive shaft to restrict inlet

• Accepts larger feed stock

• High speed grinding action, ideal for dry granulation

Top driven direct drive

• An alternative for ‘hopper feed’

installations

• Compact

• High torque, slow speed applications

Top driven module

• Bare shaft

• For connection to customers’

power units

• Ideal for fitting directly to the

outlet of a drier

In-line under-driven direct drive

• No drive shaft to restrict inlet

• Accepts larger feed stock

• Slower speed grinding action, ideal for

wet granulation

THE RANGE CONTINUED

Remote location in-line under-drivendirect drive

• As in-line under-driven direct drive, except that the

drive is located separately from the milling chamber

• Ideal for clean room operation

• A practical solution for explosive environments

Again through our extensive applications experience,

we have developed some key construction options

to satisfy individual process, operational, cleaning

and installation requirements. We are always willingto develop our Cone Mills further in pursuance of our

customers’ operational challenges.

Customising options - Milling Chamber Housing

In addition, we offer KEK Cone Mills for

hazardous area operations which include:-

• Flameproof electrics

• Hydraulic drives

• None-sparking materials of construction

• Inert gas purging

Swing away dischargechute

• Top drives only

• Easy cleaning

• Rapid cone changes

• Easy rotor clearance adjustment

• Ideal for mobile machines and

bagging-off applications

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cone mills

kemutecSpecialists in Powder Processing Technology

Side access discharge chute

• Hinged or removable access door on discharge

chute

• Discharge chute is accessible for easy cleaning

• The cone can be easily removed or replaced

• The rotor is easily accessible for adjustment

• Ideal for fixed or in-line installations

Mast mounted Cone Mills

• Cone Mill can be swung off-line to the side

• Facilitates raising or lowering for cleaning or

grinding media changes

• Enables Cone Mill to be replaced by a make-up

piece when product does not require processing

Hinged orremovable

access door

In addition, our comprehensive range can readily

accommodate any of the following process

requirements:-

• Fully mobile Cone Mills

• Explosion containment up to 10 bar

• Explosion suppression systems

• Fully flushable CIP

• Spray ball CIP

In-lineprocess

Pull through Cone Mills

• In-line vacuum conveying systems

• Continuous dust-tight operation

• Less risk of contamination

Rise andfall mast

Rotatablemast

APPLICATIONS

Granulationa. Pharmaceutical Wet Granulation

To process ‘wet mass’ product from a High SpeedMixer and produce small ‘nodules’ with a large surfacearea to weight ratio to maximise the efficiency of theonward drying process

Kek in-line Cone Mill with under-driven grinding media

• Full bore opening provides no restriction to incomingproduct

• Sealed gearbox providing hygienic, slow speed drive– ideal for the wet granulation process

The need

The solution

The benefits

The need

The solution

The benefits

To grind or ‘granulate’ product after the drying process(see ‘Wet Granulation’ above). Prior to tableting

Kek belt drive Cone Mill with over-driven grinding media

• High speed grinding through belt drive to providehigh impact milling action

• Sealed ‘drop through’ installation – ideal forenclosure within a downflow booth

• Ideal for mobile machines and bagging-offinstallations

b. Pharmaceutical Dry Granulation

High shearmixer

Kek in-line Cone Mill (direct under-driven) – slow speed in-line process

Move IBC to drier feed

Collect in IBC

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cone mills

kemutecSpecialists in Powder Processing Technology

Inflatable seal

The need

The solution

The benefits

To grind reject or scrap product and to recycle back intothe original process as a small percentage of the totalvolume, or to produce material which is the basis of aproduct in its own right

Kek belt drive Cone Mill with over-driven grinding media

•In-line dust free operation •Low energy, short residence time Cone Mill action

ensures minimal heat transfer into product obviatingfat melt

•Fine ground product achieved in one pass and idealfor adding back to the original process

Typical bakery/confectionery re-work applications:-• Cream biscuits• Agglomerated boiled sweets• Chocolate bars• Bread crumbing• Rusk milling• Biscuit grinding for dessert bases

Kek belt driveCone Mill – high

speed dropthrough process

Downflowbooth

Drumcollection

Fluid beddrier

Biscuit and confectionery re-work

c. Other granulation applications• Detergent ingredients and tablets• Babyfood flakes• Spice de-agglomeration• Graphite• Sugar grinding• Brown (demerera) sugar de-agglomeration

Ground biscuit

Other applications

• Pharmaceutical tablet reclaim• Detergent tablet reclaim• Mint crystal grinding• Milk powder de-agglomeration

Hand tip biscuits

Adjustable gate

Belt conveyorKek belt drive Cone Mill

Mobile bin

Ground biscuit

KEMUTEC

Kemutec

Kemutec is well established as a leadingmanufacturer of dry bulk solids processing andhandling equipment of outstanding quality. Ourspecialist technologies are particularly suited toapplications in the food, pharmaceuticals, plastics

and chemicals industries. Besides cone milling, theyinclude other size reduction techniques, mixing/blending, sifting and solids flow control.

Partnership with customers and emphasis on service are the corner-stones of our success. Ourengineers work directly with customers to design andbuild equipment for specific applications each basedon proven experience in the technologies in whichwe excel.

We have modern, purpose built ISO 9001 accreditedmanufacturing facilities. We place particular

emphasis on surface finishing, whatever the material.Mirror polishing of crack and crevice free equipmentconstructed from stainless steel is a particularspeciality, reflecting our commitment to excellenceacross the full product range.

Packaged engineering

In addition to the manufacture of individual machines,

our extensive experience makes us well placed to

design, manufacture, install and commission

processing packages including the associated

pneumatic (or other) conveying systems, support

structures and controls.

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cone mills

kemutecSpecialists in Powder Processing Technology

Technology Centre

Our policy is to ensure that our customers have the

best opportunity to test our equipment in a location

and framework which enables them to make a

realistic assessment of its suitability for their

particular needs.

Accordingly, we operate two comprehensively

equipped ‘technology centres’ one of which is

located at our UK headquarters and the other at our

North American base in Bristol, Pennsylvania where

trials on customers’ materials can be carried out with

a representative from the customer in attendance or

not, as the customer chooses.

Both sites are equipped with both production and

pilot size Cone Mills where short to medium duration

tests can be carried out in a controlled environment

which allows full characterisation and recording of

the trial results.

Hire facilities

As an alternative to trials within our technology

center we are able to undertake trials at customers’

premises. This is particularly desirable where the size

reduction process needs to take place while the

product is in a specific condition or where it is of a

nature requiring a high degree of containment. We

offer test units complete with a full range of cones

and beater options. Each machine has an electronic

variable speed control with speed indication. To

complete the monitoring program, we provide

load meters and hours run indicators too. Trials

machines are available to meet the European and

North American standards for operation in hazardous

environments where solvents or explosive powders

may be present.

After Sales Service

At Kemutec, we believe that the trials and delivery of

equipment are just the beginnings of what will

become a long term relationship. To ensure the

smooth operation of our customers’ production, not

only is our equipment robustly designed for longevity

but we offer planned maintenance schedules and

hold a comprehensive stock of wear parts and other

key components.

Kemutec130 Wharton RoadBristol, PA 19007Telephone:215 788 8013E-mail:Sales@KemutecUSA.com

Website:www.KemutecUSA.com

Kemutec has its own sales office in the USA and has a comprehensive network of representatives throughout theindustrialised world, all able to provide applications engineering, sales and service.

OUR OTHER PRODUCTS

GARDNER MIXERS & BLENDERSWe offer an extensive range comprising laboratory

mixers, ribbon mixers, ploughshare mixers,

continuous mixers, reactors, processors, double

cone blenders and drum blenders.

KEK CENTRIFUGAL SIFTERSCompact, high efficiency sifters for throughputs up

to 100 tph. Most have cantilevered drive shafts

reducing the number of bearings and seals - offering

major benefits for hygiene and cleaning.

KEK KIBBLERSDesigned to accept lumps up to 150mm dia. and

reduce them down to 2 or 3 mm within a narrow

particle size distribution and with minimal fines at

rates ranging from 2 to 25 tonnes/hour.

Our skilled and experienced, professional engineeringstaff are well qualified to discuss, analyse, evaluateand produce a cost effective solution to meet yourpowder processing and handling requirements.

Talk to us, to find out how we can help you to achievegreater productivity, new processes and increasedprofitability.

KEK UNIVERSAL MILLSFor the fine grinding of food, pharmaceutical and

chemical materials of up to 3 Moh hardness to within

the range of 30 to 500 micron mean particle size.

Kemutec Also Supplies:Ø Kek Centrifugal SiftersØ GKM Tumbler ScreenersØ Kek Univesal MillsØ Kek Cone MillsØ Kek Kibbler Lump BreakersØ PPS Air Classifier MillsØ Gardner Mixers and BlendersØ Mucon Valves and Discharge Aidskemutec

Specialists in Powder Processing Technology