IPA boasts a robust team with a distinctive shared history of collaboration, where each partner brings a wealth of experience, expertise, and innovative ideas to the table. With years of direct engagement in turnkey roller compaction installations, we have honed our skills and knowledge to perfection. The inception of IPA has empowered us to break free from constraints of big company logic, enabling us to reimagine equipment design, rectify flaws, and craft increasingly efficient solutions tailored to our clients’ needs.
Setting us apart from competitors is our ability to configure optimal setup of all system parameters, a process that demands a delicate balance and a profound understanding of the equipment. We meticulously consider each component of the system, recognizing how each piece must integrate with the next to form an effective solution.
Roller Compaction –
At the core of roll compactors lies a fundamental task: two counter-rotating rolls compress material to form a compact sheet. What distinguishes us is our innovative Twin Feed Screw Design. The IPA Roll Compactor’s unique twin feed screw design excels at processing lower bulk density powders with high air content, affording independent control over feed rate and material deaeration. The HFS controls system throughput, while the VFS efficiently deaerates the powder. Additionally, the VFS enables pre-compression by expelling air between particles without compacting the material. Subsequently, the material enters the Nip area, achieving tapped bulk density (TBD). The friction between the roll surface and material facilitates its entry into the counter-rotating rolls, where the primary compaction occurs.
Our dry granulation process maintains lower system operating temperatures and yields higher product yields compared to single feed screw designs. The IPA Roller Compactor is ideal at processing a diverse range of materials.
Size Reduction –
When it comes to size reduction, the optimal method for processing roll-compacted material is with the fixed-blade IPA Mill. Through extensive side-by-side research with various materials, the IPA Mill (a comminutor mill) has emerged as the most effective unit for delivering consistent, repeatable results.
The IPA size reduction process employs an “in-air” impact method, which shatters material along its natural fracture points, resulting in the highest first impact yield. This technique minimizes the percentage of material requiring a second impact, maintains lower product temperatures, and reduces fines generation, making it the most efficient approach.
Versatile and adaptable, the IPA Mill can be configured for use with a wide variety of roll-compacted materials. By adjusting mill features such as feed throat, rotor styles, and screen type, this industry “Workhorse” consistently produces the desired final product with precision and reliability.
