KAISER Process and Belt Technology, Germany

Pastillation THE METHOD OF CHOICE FOR CHEMICAL & FOOD MANUFACTURERS!

Pastillation provides an efficient, cost effective process for the continuous converting of molten products into uniform, round and dust free granules ideal for bagging, transporting and bulk material handling systems.

The Pastillation process has the flexibility to produce pastille sizes ranging from 1-25 mm in diameter and with viscosities ranging from 5 – 30,000 mPas (cP), based upon processing conditions and need.

From Pastillator heads to complete turnkey units, up and down stream equipment, our company can provide customized solutions for your Pastillation process.

Rollomat®

The Rollomat® system, initially developed in 1989 by Comp. KAISER, covers the widest viscosity range of all rotating Pastillators. The Rollomat® rotary depositor has an operating principle similar to a gear pump.

The heart of this system is an inner-geared, hollow cylinder with nozzles positioned, between the teeth. Along the lower portion of the hollow cylinder a pressing roll engages with the teeth of the hollow cylinder and the product is fed at the designated rate through the plug in lance.

From where it flows onto the rotating pressing roll and becomes sandwiched between the outer cylinder and inner pressing roll. Each time the teeth of the hollow cylinder engage with the teeth of the pressing roll product is forced through the nozzles and onto the cooling belt. The Rollomat® has a heated product scraper (refeed bar) ensuring the outer surface of the cylinder is clean upon reaching the drop-off point.

Benefits:

Ideal for running products with higher melting points Lower operating temperatures Wide range of product applications Compact design Two internal wear parts that typically last 5-6 years. Industry standard bearings and parts as much as possible. Heating hood. To keep product viscous and not build up on shell Triangular pitch shell for maximum capacity and belt loading Scraper bar flips for easy packing replacement. Does not require a large swing out arm. Packing material is standard pump packing Product is pressed out of shell. This results in product that is more consistent in size

and shape. Unit is not under pressure which results in no product leaking out of bearings. Impeccable Safety Record. No injuries since market introduction over 25 years ago!

                KAISER Process and Belt Technology, Germany

Rollomat® Functional diagram:

Typical products:

Aluminium sulphate, Bitumen, Caprolactam, Castor oil, Chocolate, Chromic acid, Epoxy resin, Fertilizers, Ketonic resin, Modified stearic acid, Modified waxes, Petroleum resin, Phenolic resin, Polyamide resins, Polyester resins, Polyethylene waxes, PVC additives, Rosin resins, etc.

KAISER Process and Belt Technology, Germany

Rollosizer®

The rotating pastillation process Rollosizer® is our most recent development, and is complementing our other pastillations systems, when it comes to achieve high capacities on one unit with low viscosity products. We utilized for the design of the KAISER Rollosizer® the various advantageous features of the KAISER Rollomat®, which is successfully in use for many years at various operations.

The drop-forming principle is a static heated cylinder with the inner product channel and the tubes for the heating medium. By means of a special product distribution bar, the product enters the cooling belt through the holes in the perforated outer cylinder. The pastilles are generated by the overlapping of the holes in the product distribution bar with the holes in the outer rotating cylinder.

The product refeed bar collects the surplus material right after the drop-forming principle and pushes it back into the holes of the outer rotating cylinder.

The sealing of the product is done very similar to the design of the KAISER – Rollomat® by means of simple and easy to re-place O-rings and soft packings and we abandoned all kinds of mechanical seals.

Benefits:

Ideal for running products with higher capacities and low viscosities The exchange of the hollow roller of the KAISER – Rollomat and the rotating, perforated

cylinder and of the product distributions pipes and pressing gear is possible with very little efforts, so each Rollomat® could be converted into a Rollosizer® and vice versa. That means all possible products which could be pastillated, could be produced with basically one pastillation unit.

Wide range of product applications Compact design Minimal internal wear parts Industry standard bearings and parts as much as possible Heating hood. To keep product viscous and not build up on shell Triangular pitch shell for maximum capacity and belt loading Scraper bar flips for easy packing replacement. Does not require a large swing out arm. Packing material is standard pump packing Unit is not under pressure which results in no product leaking out of bearings. Impeccable Safety Record.

KAISER Process and Belt Technology, Germany

Rollosizer® Functional diagram:

Typical products:

Sulphur, Urea, Waxes, Paraffin, Caprolactam, Fatty alcohols and fatty acid products, etc.

KAISER Process and Belt Technology, Germany

The ZN System

The ZN System, predecessor the“DN,” from KAISER originated in 1953 making it the first Pastillation process invented.

The ZN System operates on a drop forming principle achieved through the up-and-down motion of the needle inside the nozzle.

The pastille size is primarily determined by the diameter of the needle and nozzle, the liquid level inside the tub and the number of needle strokes.

Benefits:

Low cost solution for low to medium capacities Processing of extremely low viscosity products Electrical heating capabilities Gastight housing available Feeding temperatures up to 400° C (752º F)

The ZN System Functional diagram:

Typical products: Acetanilide, Bisphenol A, Caustic soda, Disodiumtetrasulfide, Fatty acids, Fatty alcohols, Laurinlactam, Maleic anhydride, Monoglyceride, Neopenthylglycole, Paraffins, Pet food, Potassium soda, Succinic anhydride, TMA, TNT, TPP, Waxes, etc.

KAISER Process and Belt Technology, Germany

The GS System

The GS System, originally developed in the 60ties by KAISER PBT, is designed for medium to high viscosity products.

Contrary to the ZN System, the needles are replaced by a cylinder and piston arrangement.

The up- and-down movement of the cylinder and piston allows the molten product to be deposited on to the belt creating uniform pastilles.

Benefits:

Low cost solution for high viscosity products Only solution for products with a temperature over 300° C (572º F)

The GS System Functional diagram:

Typical products:

Antioxidants, Atactic polypropylene, Bitumen, Coal tar pitch, Depilatory wax, Gelantine, Hotmelts, Hydrocarbon resins, IC – resin, Novolac resins, Phenolic resins, Polyethylene wax, Sodium-alkylsulfonate, Softeners, TMQ, etc

KAISER Process and Belt Technology, Germany About us Our company is located in Krefeld, Germany near Düsseldorf International airport. We have over 50 years of experience in the solidification of molten products on continuous belts. In addition to our core business we design, manufacture, deliver and install up and downstream equipment. Therefore, being the number 1 choice when it comes to "FROM MELT TO SOLID" Our core business is Pastillation units which continuously convert molten product, through means of a Pastillator head, into uniform, dust-free granules. The Pastillator head deposits the drops onto an endless steel belt which is cooled from underneath, with no product contact, achieving solidification. We are the only company in the world offering several different Pastillation systems, which were designed and patented by us over the last decades. With our experience and know-how we can accommodate all products capable of being Pastillated. That includes low viscous, amorphous melts and high viscous polymers. We deliver units for corrosive products, for melts with solid particles and for products with super-cooling effects. Our goal is to offer our clients a high quality solution with the most up to date technology while sustaining our environment through high energy efficiency. In addition to Pastillation units, our company offers a wide range of cooling conveyors tailor-made to our clients’ requirements. This includes strip granulation units and flaking units as single belt or double belt coolers. On double belt coolers the product is cooled in between two belts minimizing the cooling length and time saving the necessary space for the cooling belt unit. The cooling belt is considered the heart of a complete solidification unit. Based on our experience of 60+ years in the design, manufacture, delivery and installation of such units we act as the general contractor for many of our clients requiring complete units consisting of: melt reactors, holding tanks, pumps, filters, piping, granulation equipment including belt cooler, storage, bagging and palletizing units as well as the delivery of utility units such as steam, thermal oil or cooling water equipment. For over 20 years we have been delivering turnkey units for the manufacturing of solvent-free industrial adhesives, so called “hot melts“ and “melt pressure sensitive adhesives“. For these products we developed melting reactors with specially shaped double helix mixing elements. For melt pressure sensitive adhesives we successfully developed a new process for the packaging of these products into a film bag. With the new KAISER PBT Bag Filling Process it is now possible to continuously package these products into sealed bags. The film material has a low melting range and will be melted together with the adhesive. We deliver special units, including belt reactors and fully automated units for the production of 5 kg - wax slabs. We are able to provide the best service to our clients worldwide together with our local sales and service agents. With a highly sophisticated and well equipped test center in Krefeld, Germany we are continuously developing our systems to improve the existing processes and invent new systems based on our clients’ needs. The test center can be used by our clients for demonstration and scale-up purposes. Due to our product database of 8,000+ previously tested products we are many times able to design new units without additional testing.

For more information or to find your local representative please contact us.

KAISER Process and Belt Technology GmbH Siemensring 54-56

Willich D-47877 Germany

Phone: +49 2154 891070 Email: info@kaiser-pbt.de

Website: http://www.kaiser-pbt.de/EN/