TURNKEY SOLUTIONS, PROJECT ENGINEERING, PLANNING AND MAINTENANCE FOR THE BULK SOLIDS, RAW MATERIALS HANDLING AND PROCESSING INDUSTRIES CALL NOW ON 01858 462806 OR EMAIL INFO@ORTHOSPROJECTS.COM

Products

Orthos Projects specify, design, manufacture, supply, install and commission a range of quality process plant and equipment including Eirich Intensive Pan Mixers for which they have represented and acted as agents (within the foundry industry) for Eirich in excess of 30-years.
Engineers, operators and manufacturers involved in the processing of bulk solids and raw materials, know that to produce top quality products, and to keep their plants operating at a high efficiency rates, they must invest in the correctly specified and built for purpose process plant and equipment. This is where the name ORTHOS stands for top class quality and efficiency.


Orthos Projects only specify and supply quality products to enhance their world-class installations.
Within the foundry industry Orthos specialise in systems for processing bentonite-bonded moulding sand, and operate and have a reputable presence within the other bulk solids and raw materials processing industries, turning out process plants and equipment without compromise on quality or efficiency.

Eirich Intensive Pan Mixer D-Type

Users in the foundry industry know that to get the most out of their state-of-the-art moulding lines, the moulding sand has to considently meet very stringent quality criteria. The name EIRICH stands for top class quality.

Orthos specialise in systems for processing bentonite-bonded moulding sand, and for over 30-years has represented Eirich in the UK as sole agents for the foundry industry.

The ‘D’ and ‘R’ series intensive pan mixers were developed for the most diverse jobs in the processing of raw materials, mechanical mixtures and compounds, either as a batch or continuous process. Variable setting of machine components and the energy range ensure a high degree of efficiency.

 

Three components determine the characteristics of these mixers: 

  1. A horizontal rotating mixing pan, inclined on the R-type
  2. Rotating mixing tools
  3. An adjustable multi-purpose wall-bottom scraper

The unique mixing principle of the Eirich Mixer is:

  1. The rotating mixing pan, for material transport
  2. High-speed rotor tool, for mixing
  3. The effect is the separation between material transport and the mixing process allows a maximum input of power to be introduced into the moulding material with minimal wear.

This mixing principle enables:

  1. Optimal disintegration of bentonite
  2. Quick and homogeneous distribution of water
  3. Complete and even coating of sand grains with binder, carbon carrier and fines
  4. Increase in productivity through higher moulding material quality

Eirich design and manufacture very high intensity pan mixers – the workhorse of industry, catering for capacities from 1 to 12,000 litres.

Eirich Intensive Pan Mixer R-Type

The ‘R’ series intensive pan mixers were developed for the most diverse jobs in the processing of raw materials, mechanical mixtures and compounds, either as a batch or continuous process. Variable setting of machine components and the energy range ensure a high degree of efficiency.

Three components determine the characteristics of these mixers:

  1. An inclined rotating mixing pan, horizontal on the D-type
  2. Rotating mixing tools
  3. An adjustable multi-purpose wall-bottom scraper

The unique mixing principle of the Eirich Mixer is:

  1. The rotating mixing pan, for material transport
  2. High-speed rotor tool, for mixing
  3. The effect is the separation between material transport and the mixing process allows a maximum input of power to be introduced into the moulding material with minimal wear.

This mixing principle enables:

  1. Optimal disintegration of bentonite
  2. Quick and homogeneous distribution of water
  3. Complete and even coating of sand grains with binder, carbon carrier and fines
  4. Increase in productivity through higher moulding material quality

Eirich design and manufacture very high intensity pan mixers – the workhorse of industry, catering for capacities from 1 to 12,000 litres.

 

Moulding Sand Measurement and Control System

To complement the mix processing of foundry moulding sand and to guarantee sand of constant high quality, Eirich manufacture the QualiMaster AT1. The unit is installed in the prepared sand line directly downstream from the intensive pan mixer; it is equipped with an autonomous local controller (PLC) for simple adjustment and monitoring. The unit will test for compactability, shear strength and as an option compressive strength. This coupled with the SandReport software will display statistical analysis, and with the SandExpert software following analysis the values are made available to the plant control system which will automatically correct the moisture content and adjust the additive feed optimising the moulding sand.

Moulding Sand Aerator

Following the casting shakeout/knockout process the return sand will require the lumps breaking down and re-aeration in preparation for the next process. A moulding sand aerator is required for this process, units are available in various sizes dependant on width of the conveyor belt and required throughput. These units are designed and built to be rugged and long lasting when employed in the arduous conditions of the foundry.

Rotary Table Feeders

For continuous mixing applications, it is necessary to meter and control the sand being processed through the mixer ensuring optimal resonance time. This is a function of the Rotary Table Feeder, this unit will meter the output of the sand for the downstream processing, coupled with the control of the material in-feed conveyor into the mixer the optimal mix processing time will be achieved. Rotary Table Feeders are available in various capacities and with a single or twin discharge point.

Foundry Sand Coolers

Varieties of sand cooling methods are available, but most have drawbacks and are inadequate for today’s foundries. Following the casting separation and shakeout process, the temperature of the sand averages around 150°C, however at times it can be as high as 200°C. Modern moulding lines require cool, consistent sand temperatures which may vary, but the sand should never exceed 45°C. Putting sand through the moulding system at higher temperatures reduces mould making efficiency and casting quality problems, which results with an increase in scrap.

The Orthos Projects sand cooler is an efficient unit based on a combination of the incoming sand being blended with cooled sand already being processed; this is achieved via a figure-of-eight mixing pattern by counter rotating mixing stars, which effectively operates on the principal of evaporative cooling where both air and water are introduced into a mechanically fluidized mass of sand.

Moisture and temperature control are achieved through monitoring sensors on the feed and discharge sand conveyors, this coupled with a plc control ensures water addition and cooling air at a precise controlled rate result in consistent sand properties.

Our sand coolers are installed in foundry plants both in the UK and overseas, processing up to 130tph of return sand.

The Orthos Projects sand cooler meets all the needs of a modern foundry. Compared with other cooling techniques, it provides more efficient and consistent cooling keeping the sand in a consistent condition with the mixing and blending action averaging out any variations in additives.

Storage and Weigh Hoppers and Bins

Orthos Projects manufacture bins and hoppers to suit a wide range of bulk solids material handling applications. Screw conveyors, belt conveyors, elevators, pneumatic conveyors and screw bin dischargers are very often used to fill and discharge bins, weigh hoppers and small intermediate storage bins. All bins and hoppers are designed and built to precise customer requirements – with many options available.

Weigh Feeders and Belt Weighers

Volumetric weigh feeders, loss in weight feeders and continuous belt weighers provide accurate monitoring of process material ensuring all process parameters are met by reducing material waste and improving plant efficiency.

Volumetric weigh feeders and loss in weight feeders are designed and built to suit the application and process requirements.

Our belt weighers offer continuous monitoring and measurement of the mass flow of bulk solids at high to low speeds and feed rates.

Bin Dischargers

Bin Dischargers are used to solve the numerous problems of handling and discharging poor flowing bulk materials. Bulk materials that are cohesive, have a tendency to bridge but can be but fluidized, can be reliably and effectively discharged into the down stream process.

Belt Conveyors

Orthos Projects designed and purpose built belt conveyors and systems are both reliable and durable. Manufactured from only the best quality materials and components and driven by drive units and gearboxes supplied from reliable and top quality motor manufacturers. Orthos Projects Bulk Material Conveyors are robust and perform in the harshest of environments from the foundry to recycling to quarried stone, and offers an enviable reliability. Orthos Projects have gained a reputation for supplying top quality conveyor systems resulting in many repeat orders and recommendations from satisfied customers.

We manufacture conveyor belts to suit every bulk solid and raw material application, our conveyor designs include, inclined, declined, troughed belt, flat belt, side wall belt, chevron belt, high impact belt. The systems can be designed to incorporate, belt weighers, samplers, ploughs, metal detectors, inline and cross-belt magnets, eddy current separators, infrared and moisture measurement control.

Pneumatic and Vacuum Conveying Systems

Pneumatic and vacuum conveying systems are a safe and efficient means of transferring dry bulk powders and granulated products, eliminating the potential risk of spillage, leakage and cross contamination. The systems also lend themselves to difficult to route cross-plant transfers, since the conveyor lines can be routed vertically and horizontally in any direction, over short or long distances. Orthos Projects design and build pneumatic and vacuum conveying systems to suit many bulk material transfer applications. Our engineers will assess each application and advise of the most efficient system for your particular requirement. We supply both dilute/lean phase and dense phase systems, utilizing pressure vessels and compressed air or ‘roots’ type blowers. Vacuum systems are effective as they operate under a negative pressure where the potential leakage of product is prevented, however the throughput quantity of material to be conveyed is limited due to the negative pressure that can be created.

Belt and Bucket Elevators

On some plant designs with restricted floor area and varying floor levels, vertical bucket elevators offer the ideal solution. Orthos Projects design and build bucket elevators utilizing the latest technology and quality components. Each elevator is bespoke built for each application ensuring your product is transferred efficiently and meeting the throughput required. Various additional options are offered, including belt tracking monitoring and explosion relief panels. Our elevators work and operate in the most arduous conditions withstanding high temperatures and 24-hour operation.

Dockside Mobile Loaders (DML’s)

Dockside Mobile Loaders (DML’s) are environmentally friendly mobile hoppers for the grab unloading of ships bulk dusty cargoes. With the launch and application of new products during the last few years, Dockside Mobile Loaders (DML’s) have gained a technological lead in the elimination of spillage, controlling dust and incorporating aspects of tribology. In the design of bulk solids applications grab unloading of dusty cargoes using DML’s has been proven to be successful in satisfying increasingly stringent EPA limits and complying with European legislation.

DML’s are a cost effective method of grab unloading compared to the high capital costs associated with semi-automatic and automatic continuous ship unloaders. Particularly at smaller ports where dock space is restricted and a number of different products are handled, providing environmentally stringent limits can be adhered to. The Orthos DML achieves these limits.

Bespoke Products & Process Equipment

Orthos Projects specify, design, build and supply bespoke products and equipment for various bulk solids and raw materials handling, storage and processing applications, providing the vital link between process steps, and as part of the service we offer the installation, commissioning and after sales support to complete the package.

We only specify and build quality plant and process equipment to enhance our world class installations. Listed below is a range of process equipment and products on offer, if your particular requirement is not listed below, please do not hesitate to contact us.

Eirich Intensive Pan Mixers (Foundry) • Eirich QualiMaster AT1 Moulding Sand Measurement and Control System • Moulding Sand Aerator • Rotary Table Feeders • Foundry Sand Coolers • Storage & Weigh Hoppers & Bins • Weigh Feeders • Bin Dischargers • Belt Conveyors • Pneumatic & Vacuum Conveyors • Belt & Bucket Elevators • Dockside Mobile Loaders

 
 
Authorised resellers of Eirich for the UK Foundry Industry

End-to-end turnkey planning, maintenance and service for industry

Contact us today with your project needs or service requirements, and a member of our team can be appointed to assist you further.

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