As a supplier of drum flakers, I'm often asked about how these remarkable machines work. Drum flakers are essential pieces of equipment in various industries, including chemical, food, and pharmaceutical, for converting liquid or molten materials into solid flakes. In this blog post, I'll take you through the inner workings of a drum flaker, exploring its components, the operational process, and the different types available.
Components of a Drum Flaker
A drum flaker typically consists of several key components, each playing a crucial role in the flaking process.
Drums
The drums are the heart of the drum flaker. They are large, cylindrical metal structures that rotate slowly. In a double drum flaker, there are two drums positioned parallel to each other with a small gap between them. The drums are usually made of high - quality stainless steel or other corrosion - resistant materials to withstand the harsh conditions of the flaking process. The surface of the drums is carefully polished to ensure smooth operation and good heat transfer.
Feed System
The feed system is responsible for delivering the liquid or molten material to the drums. It can include a hopper, a pump, and a distribution mechanism. The hopper stores the material, and the pump transfers it from the hopper to the distribution system. The distribution system evenly spreads the material across the width of the drums. This ensures that the material forms a uniform layer on the drum surface, which is essential for producing consistent flakes.
Cooling System
To convert the liquid or molten material into solid flakes, the drums need to be cooled. The cooling system circulates a cooling medium, such as water or a refrigerant, through the interior of the drums. As the hot material comes into contact with the cold drum surface, heat is transferred from the material to the cooling medium, causing the material to solidify. The cooling system is carefully designed to maintain a constant temperature on the drum surface, which is critical for the quality of the flakes.
Scraper
Once the material has solidified on the drum surface, a scraper is used to remove the flakes. The scraper is a sharp blade that is positioned close to the drum surface. As the drum rotates, the scraper gently scrapes the solidified flakes off the drum, allowing them to fall into a collection chute below. The scraper is adjustable, so its pressure against the drum surface can be optimized to ensure efficient flake removal without damaging the drum.
Drive System
The drive system is responsible for rotating the drums. It typically consists of an electric motor, a gearbox, and a chain or belt drive. The motor provides the power, and the gearbox reduces the speed of the motor to the appropriate rotational speed for the drums. The chain or belt drive transfers the power from the motor and gearbox to the drums. The drive system is designed to provide smooth and consistent rotation, which is important for the quality of the flakes.
The Operational Process of a Drum Flaker
The operation of a drum flaker can be divided into several steps:
Feeding
The process starts with the feeding of the liquid or molten material into the hopper of the feed system. The pump then transfers the material from the hopper to the distribution system, which spreads the material evenly across the width of the drums. The amount of material fed onto the drums is carefully controlled to ensure that the layer of material on the drum surface is of the right thickness.
Solidification
As the drums rotate, the liquid or molten material comes into contact with the cold drum surface. The cooling medium circulating inside the drums absorbs the heat from the material, causing it to solidify. The rate of solidification depends on several factors, including the temperature of the material, the temperature of the cooling medium, and the rotational speed of the drums.
Flake Removal
Once the material has solidified on the drum surface, the scraper removes the flakes. The flakes fall into a collection chute below, where they can be further processed or packaged. The thickness and size of the flakes can be adjusted by changing the gap between the drums, the rotational speed of the drums, and the amount of material fed onto the drums.
Types of Drum Flakers
There are several types of drum flakers available, each designed for specific applications.
Double Drum Flaker
The Double Drum Flaker is one of the most common types of drum flakers. It consists of two parallel drums that rotate in opposite directions. The material is fed into the gap between the two drums, where it is squeezed and cooled to form flakes. Double drum flakers are suitable for a wide range of materials, including polymers, waxes, and food products.
Condensing Drum Flaker
A Condensing Drum Flaker is used when the material needs to be condensed before flaking. In this type of drum flaker, the material is first vaporized and then condensed on the cold drum surface. The condensed material is then scraped off the drum to form flakes. Condensing drum flakers are often used in the chemical industry for processing volatile materials.
Cooling Drum Flaker
The Cooling Drum Flaker is designed primarily for cooling and solidifying molten materials. It has a single drum or multiple drums that are cooled by a circulating cooling medium. The molten material is fed onto the drum surface, where it solidifies as it loses heat to the cooling medium. Cooling drum flakers are commonly used in the food and pharmaceutical industries for processing products such as chocolate, fats, and waxes.
Advantages of Using a Drum Flaker
There are several advantages to using a drum flaker in your production process:
High Efficiency
Drum flakers can process large volumes of material in a relatively short period of time. The continuous operation of the drums allows for a high throughput, making them suitable for industrial - scale production.
Consistent Product Quality
The controlled cooling and flaking process of a drum flaker ensures that the flakes produced are of consistent quality. The thickness, size, and shape of the flakes can be precisely controlled, which is important for applications where product uniformity is critical.
Versatility
Drum flakers can be used to process a wide range of materials, including liquids, molten substances, and even some semi - solid materials. This versatility makes them a valuable asset in many different industries.
Energy Efficiency
The cooling system of a drum flaker is designed to be energy - efficient. By using a circulating cooling medium, the amount of energy required to cool the drums is minimized, reducing operating costs.
Conclusion
In conclusion, drum flakers are sophisticated machines that play a vital role in many industries. Their ability to convert liquid or molten materials into solid flakes efficiently and consistently makes them an essential part of the production process. Whether you need a Double Drum Flaker, a Condensing Drum Flaker, or a Cooling Drum Flaker, we have the expertise and the equipment to meet your needs.
If you're interested in learning more about our drum flakers or would like to discuss a potential purchase, we encourage you to reach out to us. Our team of experts is ready to assist you in finding the right drum flaker for your specific application and to provide you with all the information you need to make an informed decision.
References
- Perry, R. H., & Green, D. W. (Eds.). (2008). Perry's Chemical Engineers' Handbook. McGraw - Hill.
- Cheremisinoff, N. P. (2003). Handbook of Industrial Drying. Marcel Dekker.