News | March 27, 2002

A Propensity For Chip Density

Source: Mayfran International, a subsidiary of Tomkins
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The new FastPacTM Briquetter from Mayfran International (Cleveland, OH) transforms mounds of metalworking chips, strings and nests, fines and sludge into dense, dry and compact briquettes. The FastPac series of briquetting machines can pay for itself in one year or less of use by increasing the values of scrap ferrous and nonferrous materials and lowering costs and frequency of removal. The series also minimizes spill liability risks during transport by increasing the amount of coolant and cutting fluids reclaimed. It also reduces the need for large scrap storage areas and helps users keep better track of scrap volumes and weights while providing a cleaner, safer, more efficient work environment. FastPac's dual-stage compacting process and dual-action compression/ejection cycle requires less horsepower, thus lowering energy consumption and operating costs. In addition, FastPac's compact design results in a space-saving footprint of the machine. All briquetters are tested for extended periods at the factory prior to delivery and installation usually requires little more than an electrical connection.

FastPac Briquetting systems have very low energy consumption with capacity ranges of 110 lb. all the way up to 6,614 lb. (50 kg. to 3000 kg.) of metal chips and swarf per hour. Materials, including steels, cast iron, aluminum, copper and other alloys, from a single machine, a cell, system, or an entire machining facility may be processed. The system provides an approximate 6 to8 times reduction conversion. For example, 6 to 8, 55 gallon barrels of chips will compress to one barrel of briquettes. Just as important, during the compression operation, the FastPac system will "squeeze dry" the chips, removing up to 98% of the residual coolant and cutting oils. The excess fluid drains from the compression chamber and is collected in a tray below making it available for immediate reuse or further reclamation processing. This drying process not only allows the recovery of additional, and valuable oils and coolants, it also provides added protection against high environmental clean up costs and potential fines in the event of a spill, either during transport or while in storage.

The value of scrap materials is higher, storage and floor space is saved, costs are lower, more oils and coolants can be reclaimed…and FastPac is easy to operate. Except for keeping its load hopper full (which can be automated), FastPac performs virtually unattended. A screw drive feeds the chips, strings and shavings from the hopper to the first compacting stage-- a pre-charge chamber that helps assure consistent chip volume. Maximum density will be achieved during the second, briquetting compression stage. The screw drive's running time is programmed through and monitored by a PLC control unit. The running time can be modified to optimize the pre-charge load, depending upon types of chips and materials being processed.

A ramp at the machine's discharge elevates finished briquettes to heights that will clear virtually any container or roll-off bin. Expensive equipment to elevate briquettes is not required.

When the pre-charge chamber is loaded, a secondary piston is activated to provide preliminary compression. This load is then transferred to one of two compression die chambers where the system's main compression piston transforms the pre-compressed material into a dense block. Simultaneous with the forward movement of the primary piston during the compression process, an ejector pin ejects a briquette, located in the opposite die chamber and formed during the preceding cycle, through an offload opening to a chute. As the primary piston retracts, the die chambers slide to reposition the just emptied chamber for the next compression cycle, with the completed briquette in the second chamber set in position for ejection. Meanwhile, the screw feed and pre-charger have already begun their steps of loading and pre-compression for the next cycle. This dual-stage, dual-action operation, unlike other systems typically requiring multiple strokes, means a briquette is formed with every machine cycle. This results in the FastPac systems' ability to maximize output capacity while minimizing horsepower requirements and energy consumption.

In addition to the FastPac Briquetting Systems, Mayfran International also produces a wide variety of chip handling and coolant recovery/cleaning/filtration systems for machine tools and machining operations. Included are ConSep 1000 and ConSep 2000 systems, combining at-the-machine chip conveyor/coolant cleaning in a single unit, the centralized Viavent chip and coolant handling system, conventional machine tool chip conveyors, the AT-Cleaner, a media-free system providing coolant filtering to 10 micron nominal levels, plus high pressure units and chillers, and systems for grinding operations.

Mayfran International, a subsidiary of Tomkins, P.O. Box 43038, Cleveland, OH 44143-0038. Tel: 440-461-4100; Fax: 440-461-0147.