If it’s modular you want – you got it!

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If it’s modular you want – you got it!

Our next generation 2.0 DDSR40/B and DSR67/B feeders features a modular design providing significant benefits in terms of flexibility, cleaning, sealing and improving changeover time for your production process.

Today’s manufacturing process often demand smaller lots sizes with minimum downtime. To meet these demands, feeders must be extremely reliable and have quick clean features. Brabender Technologie’s engineering team have developed the generation 2.0 line of feeder to meet these requirements.

Matching modules

Two of our most popular low-rate feeders the DDSR20 2.0 and the DSR28 2.0 have been in version 2.0 production for many months. We will soon release the model DDSR40 2.0 twin screw feeder featuring self-cleaning twin concave screw which is ideally suited for poor flowing, sticky ingredients. In addition, the DSR67 2.0 single screw feeder which is used for normal flow to cohesive ingredient applications will be released.

Jürgen Knez, Head of Product Development at Brabender Technologie, explains: “The new design approach for both these feeders focused on a perfectly matched modular design. The matching enables us to configure four feeder combinations, the DDSR40, DDSR40B, DSR67 and DSR67B version 2.0 using fewer standardized components.”

Clean and compact gear module

All components are manufactured with a compact design gear module that is attached to the drive motors. Knez explains: “The modular concept allows the larger ‘B’ screw troughs to fit the same predrilled baseplate as the standard models. This modularity can potentially allow field retrofits between models.”

The DDSR40(B) 2.0 models now feature a clean and quiet drive belt technology custom manufactured for Brabender Technologie. These drive belts now allow the twin screw gearbox to operate without lubrication eliminating maintenance while increasing lifetime.

This generation 2.0 design also eliminates the need for chains, chainguards, bearings and intermediate plates and couplings further simplifying the feeder. The gear modules operate with less noise, weigh less, and can be combined with both conventional AC motor technology and smart servo motors.

Knez summarizes: “The modular design allows the gearing units of all these feeders to be quickly and easily changed. They can be easily removed and replaced. This flexibility enables the customer to switch between large and small models or from single to twin-screw versions.”

Removable hopper with user-friendly quick release fasteners

In the new modular concept, the screw hopper is located at the front edge of the scale. “This means that the screw trough can now be easily removed from the front of the feeder, similar to the smaller DSR28 2.0 and DDSR20 2.0 versions. Feeder accessibility has been greatly enhanced and end users benefit from the ease and speed of cleaning components that come into ingredient contact,” says Jürgen Knez. What also helps are the screwless connections on trough, hopper and lids that reinforce this user friendliness. Knez explains: “We have created special captive fasteners for these hopper connections. The hopper fasteners are only rotated 90 degrees with a one size tool to loosen the connection. Everything remains in place so operators no longer have to hold loose bolts and nuts in their hands and are able to remove the hopper very easily.”

Visual check saves time

Fully transparent, dustproof outlet tees, which are made of food-grade PETG and manufactured exclusively for Brabender Technologie, are installed on all standard and B-type feeders. This hard plastic is characterized by its high transparency and shatterproof construction enabling the operator to perform visual checks inside the screw tube.

Rapid seal change

Changing rotating shaft seals has also been made considerably easier by designing a screw trough that can be removed from the front. “A new seal can be installed in five minutes,” Jürgen Knez tells us. Depending on what the customer requirements are, there are a large number of different seal types and designs available, including ATEX, food or pharma applications. An added feature of the 2.0 version are visual indicators in the bottom and top sections of the gear block assemblies to alert operators when seals need to be replaced which reduces the possibility of gearbox or motor damage.

Available servo motor

With this version 2.0 launch, we will be able to offer “smart” servo motors on all models. This servo motor has the added benefit that when compared to normal frequency-controlled AC motors, they have a much wider speed range and have full power available even at low rpm. The need to change screws and screw tubes can now be eliminated reducing downtime. At lower speeds, servo motors can start close to full torque, and even in high torque conditions they continue to have excellent speed control. Moving forward, this new generation will only feature Efficiency Class IE3 motors AC motors.

Conclusion: modular, customized, and flexible

The version 2.0 feeders will also feature reduced lead times due to the ability to stock additional standard modular components. This modularity also increases manufacturing flexibility if changes are made during the manufacturing process. The redesign combined with recent load cell technology development allows us to bridge the gap between the “smaller” DDSR20 2.0 and the “larger” DDSR40 2.0 in terms of performance and feed-rate. Jürgen Knez explains: “This enhanced design approach has enabled us to start offering customized, purpose-specific feeders that are more effective than previous generation.” Brabender Technologie will continue to develop its full product portfolio to align with the generation 2.0’s modular concept.

(published in FLUX 2/2021)