Over the course of several decades, IPA has diligently gathered insights and refined our processes to perfection, spanning from the initial testing phase through design, manufacturing, and commissioning.
Preliminary Analysis
At IPA, our commitment to excellence begins with a comprehensive preliminary analysis conducted on all feed materials earmarked for roll compaction projects. This rigorous assessment encompasses a suite of tests, including evaluating pressure versus density curves, conducting moisture analyses, and measuring tapped bulk density (TBD). These thorough evaluations furnish us with indispensable data, enabling precise configuration of the roller compactor parameters.
Applying What We’ve Learned
Preparation is paramount for conducting successful lab tests, and IPA’s approach is guided by two pivotal factors: the insights gathered from our preliminary analysis and the specific objectives outlined by the client. We diligently tailor our approach by determining optimal roll surfaces, establishing initial roll pressure set points, defining ideal compact densities, selecting appropriate mill screens, configuring screener setups, and assessing the potential benefits of vacuum deaeration. Once successful testing benchmarks are achieved, IPA harnesses all pertinent data to scale up systems that align with the client’s exacting requirements.
Scaling to a Larger System
The rationale behind our testing endeavors is multifaceted, with a primary focus on meeting the client’s diverse objectives, including particle size, density, and/or dissolution parameters. Post-achievement of these objectives, our attention shifts to optimizing system performance and scaling up operations to meet specified production rates.
To further explain this process, consider the analogy of operating a roll compaction system at varying throughput levels: from 50 lbs/hr to an industrial-scale of 3000 lbs/hr. This transition mirrors the distinction between maneuvering a compact car and navigating a semi-truck. Just as the handling dynamics differ drastically between these vehicles, scaling up from a laboratory setting to a high-capacity production environment necessitates attention to detail & design. In a larger system producing 3000 lbs/hr of final product, even minor operational hiccups can swiftly escalate into significant bottlenecks, emphasizing the critical importance of robust controls and appropriately sized equipment to maintain operational equilibrium during startup, shutdown, and flow rate adjustments.
By acknowledging the inherent challenges posed by high flow rates in large-scale systems and implementing crafted solutions, IPA remains at the forefront of innovation, ensuring seamless operation and optimal performance for our clientele.
