Product: Apples used in the apple juice production.
The farmer only takes the apples that have fallen from the tree and lay on the ground. The farmer collect’s these apples using a front-end loader and transports the apples to the processing plant.
Due to the method used in the collection process, you will find gravel, dust leafs and twigs in amongst the apples. These are mechanically removed during the washing and sorting process, the water used in this process flows to the plants screening area, where the solids and suspended solids are organic materials are removed via a fine screen water then flows through to the plants Water Treatment Facility.
The plant uses a very fine screen, to trap the floating and suspended solid with some success. However the screen would eventually become plugged with particles from the process becoming lodged between the spacing of the fine screen and eventually blinding the screen causing the liquid to back up.
When this occurs, the only recourse the plant has is to take the screen off line, remove the lodged particulates from the screen. The removal of the blocked screen, cleaning the debris from the screen and re-installing the screen takes 3 to 4 days, considering this can happen several times during season and the fact that the season only lasts 8 to 12 weeks, this is a costly inconvenience to endure.
The request from the plant was to find a way to remove both the floatables and the suspended solids from the water prior to the screen without the use of polymers.
We approach this application two folds.
First, we designed a new style drainage press conveyor, that would not become plugged with the long grass, twigs and leafs (as was happening with their existing shafted conveyor). We modified one of our industrial shaftless screw mobile drainage conveyors, installed a compaction dewatering zone. Which performs perfectly, removing and dewatering all the debris sent from the washing station, this unit is on wheels and is easily removed and reinstalled after cleaning.
The second stage was to design a new style compact classifier that could not only manage the intermittent high flows, but also have a retention time that would allow the small suspended particle and rice husks to settle out, transport and dewater the solids prior to discharging into a container. Prior to the design and manufacturing of this unit, the information on the amount of suspended solids that were captured via the fine screen was half 5 gallon pail per week. After the installation of the classifier the client remove a 10ft long x 8 feet wide x 4 feet high container per day during this season.