Flaker (Flaking Machine)

1. What is a Flaker? What is it Used For?

A flaker is a machine used to convert a melted product into solid form. As the liquid (melted product) passes through water circulating inside the rotating drum, it adheres to the cold drum and begins to solidify. After one complete rotation, the solidified surface is scraped off the drum using a scraper blade. The form, size and quality of the product depend on these factors, as well as on the process conditions to some extent. The purpose of flaking is to solidify and cool the melted product. In this way, the solidified product takes the form of fine flakes. Thanks to the flaker, the flakes produced become easier to load, unload, handle safely and transport.

2. Equipment 2.1. Drum

The drum is equipped with special internal equipment to allow cold water to circulate effectively, and is fitted with necessary components and a shaft passing through it. The drum is jacketed. The drum is specifically designed for maximum form stability. Under normal operation, distortion is impossible due to different temperature gradients. The drum design ensures uniform heat transfer for uniform flakes and is manufactured entirely from stainless steel, optionally also made from carbon steel.

2.2. Scraper System

The scraper system has a durable design and provides uniform pressure distribution across the entire length of the drum, also preventing vibration. The scraper blade running parallel to the drum perfectly scrapes off the solidified material on the surface with its sharp edges. [gallery size="medium" ids="eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDhcL3RhbWJ1cl8uanBnIiwidGl0bGUiOiJ0YW1idXJfIiwiY2FwdGlvbiI6IiIsImFsdCI6IiIsImRlc2NyaXB0aW9uIjoiIn0=,eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDhcL3RhbWJ1cl8yLmpwZyIsInRpdGxlIjoidGFtYnVyXzIiLCJjYXB0aW9uIjoiIiwiYWx0IjoiIiwiZGVzY3JpcHRpb24iOiIifQ==,eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDhcL3RhbWJ1cl8zLmpwZyIsInRpdGxlIjoidGFtYnVyXzMiLCJjYXB0aW9uIjoiIiwiYWx0IjoiIiwiZGVzY3JpcHRpb24iOiIifQ=="]

2.3. Feeding System

Pouring melted product into the bottom tank located below the drum is standard practice and process control is easier compared to top-feed systems. Additionally, a liquid level sensor can optionally be installed in the bottom tank to control the amount of melted product entering the tank. The bottom-feed type is not suitable for high-viscosity liquids. For high-viscosity products, the top-feed type is more appropriate. The thickness of the flakes can be controlled using a level roller installed on the machine. When flake thickness is controlled, solidification is facilitated. Flake thickness is related to the viscosity of the product, and if viscosity changes, flake thickness will also change. Flake thickness will be uniform thanks to the level roller. This makes it possible to achieve the same thickness at different viscosities.

2.4. Cooling System

Positive sealing between the drum and cooling circulation system is ensured by a mechanical seal. Homogeneous and effective cooling is performed on the surfaces. The flakers we produce are jacket type. Cooling water circulates within the jacket. Without delay, heated water is immediately removed from the drum.

3. Parameters

When the parameters below change, many things on the flakes are likely to change. • Drum rotation speed. • Cooling water temperature. • Gap between level roller and drum.

3.1. Drum Rotation Speed

When drum rotation speed is increased, the amount of product to be produced also increases. There is a direct relationship between drum rotation speed and cooling time. When drum rotation speed is increased, the temperature of the flakes will also increase.    

3.2. Cooling Water Temperature

When cooling water temperature is lowered, the amount of product to be produced also increases. Additionally, the temperature of the flakes will be low. However, high-viscosity liquids may not adhere to a very cold drum in some cases. When cooling water begins to warm up, adhesion to the drum will be easier.    

3.3. Gap Between Level Roller and Drum

  When the gap between level roller and drum is widened, flakes become thicker. Breaking thick flakes becomes difficult, resulting in a small amount of fine powder. When the gap between level roller and drum is narrowed, flakes become thinner and their temperature also drops. When flakes are thin, scraping them from the drum with a blade and packaging becomes easier.    

4. General Information and Technical Specifications

The flaker machine solidifies melted substances by converting them into flakes or microcrystals. It is mostly used in the food, chemical and pharmaceutical industries.

Key features;

• Compact design takes up less space, easy to use and has low operating costs. • The system produces efficient and uniform cooling, and heated cooling water is transferred to the cooling system located at the end of the shaft. • No condensation occurs due to evaporation during the process. • Features a polished drum manufactured from AISI 304 L SS or AISI 316 L SS grade stainless steel. • Features a temperature-controlled bottom tank manufactured from AISI 304 L SS or AISI 316 L SS grade stainless steel. • Sealing at cooling water inlet and outlet is ensured by mechanical seal.   Sami Ertan Technical Manager Ertanlar Paslanmaz Kimya Tesisleri Makina San. Tic. Ltd. Şti.