Spiroflow system transforms output
26 November 2007
A ‘Spiroflow’ bulk bag discharging and conveying system has been the cornerstone of the significant increase in output achieved by Carroll & Meynell Ltd
A ‘Spiroflow’ bulk bag discharging and conveying system has been the cornerstone of the significant increase in output achieved by Carroll & Meynell Ltd, a leading manufacturer of electrical transformers and other wound components. Established in 1970, Carroll & Meynell moved to impressive new premises 5 years ago to accommodate the growth in their business. Further growth in recent months has caused them to re-think and improve their production methods to keep abreast of demand. One of the major bottlenecks on their production line was the handling of the finely divided silica sand used to ‘pot’ transformers. Dry silica sand is used throughout the electrical industry as a potting medium because of its inherent insulation and thermal transfer properties.
Previously, silica sand was received in 25kg bags each of which had to be emptied into a hopper at ground level. The hopper then had to be lifted on to a platform by a fork lift truck to provide a head of free flowing sand for filling around the winding within each transformer casing. Control of the sand flow was by hand-operated ball valves. These valves used to jam open from time to time! All in all, it was a time consuming and very messy process given that Carroll & Meynell are using up to one and a quarter tonnes of sand a day!
Initially, to overcome the bottleneck, Director Bob Carroll looked at the possibility of installing a small silo to hold the sand but this would have been sited externally and would have required a lengthy conveying system. Cost was, therefore, an issue and also Bob Carroll was concerned that the super dry, super fine silica sand might pick up moisture. Any moisture in the sand cannot be tolerated as it would react with and compromise the integrity of the polyurethane resin capping deposited across the surface of the sand to keep it stable and to hold it in place.
In common with many other users of dry bulk solids, Carroll & Meynell concluded that the optimum solution was to receive their dry sand in sealed 1 tonne bulk bags (FIBC’s), to mechanically convey it up to small holding hoppers above each of 2 production lines and to have a more reliable flow control valve at the end of the sand delivery tubes.
The internet was the starting point for Bob Carroll’s search for the components required. Having once identified Spiroflow as a potential supplier of screw conveyors, a meeting with their local Area Sales Manager Peter Swinton caused Mr Carroll to realise that Spiroflow could take care of the whole system. Besides being a manufacturer of the flexible screw conveyors, with which their name is synonymous, Spiroflow produce one of the most comprehensive ranges of bulk bag dischargers in the business. A previous Spiroflow installation handling silica sand for potting electrical fuses served as an appropriate reference. This, together with, the obvious expertise of Spiroflow’s engineers, convinced Bob Carroll to place an order for the complete silica sand handling system with Spiroflow. He was so confident that he didn’t look at any alternative suppliers. However, having placed the order representatives from Carroll & Meynell did visit Spiroflow’s test centre to witness proving trials on a bulk bag discharger and flexible screw conveyor on their silica sand. This further convinced them that their decision to work with Spiroflow as right!
The installation has been in operation for 6 months now and has literally transformed the output of the 110 volt transformers produced for the construction industry, such that it is now up to 6,000 units a month – several times more than before. In fact, this increased capacity means that stock levels have been drastically cut and that even large orders from electrical wholesalers can be fulfilled almost instantly!
The Spiroflow system comprises a standard bulk bag discharger, a flexible spiral conveyor that lifts the sand 5.5 metres over a distance of nearly 5 metres, a diverter valve with tubular feed chutes to the holding hoppers, two holding hoppers with level probes (that actuate both the conveyor and the diverter valve at the conveyor outlet to ensure sand is delivered to the hopper in need of topping up), discharge chutes to the sand filling points on each of the two production lines and Mucon iris diaphragm valves to control the flow of sand. The Mucon valves were chosen because they are probably the best valves for manually controlling the flow of dry bulk solids – they do not jam! The cleanliness of the whole area around the Spiroflow system is a testament to the high degree of containment built in as standard.
Carroll & Meynell’s own engineers installed the system and, being electrical engineering specialists, they manufactured the controls system to Spiroflow’s specification. As Bob Carroll concludes, “We started to get cold feet about doing the installation ourselves having manufactured the supports to drawings provided by Spiroflow - but it was so easy to install. It was spot on, it all slotted together well! It has been doing a sterling job ever since and has eliminated both the bottleneck and the housekeeping problems on our production line”.
The Carroll & Meynell portfolio ranges from control panel transformers, through portable, site and variable transformers up to single or three phase distribution transformers. As well as manufacturing their own transformers they are a UK distributors of Cast Resin Transformers and agents for Oil Cooled Transformers. Carroll & Meynell can be contacted on +44 (0)1642 617406 or via their web site www.carroll-meynell.com.
Over 30 years ago Spiroflow were pioneers in the design and manufacture of flexible screw conveyors. They also offer aero-mechanical conveyors and over the last 20 years have become one of the UK’s leading suppliers of bulk bag (FIBC) fillers and dischargers too – specialising in high containment systems. The company operates a comprehensive test and demonstration facility and actively encourages customers to witness trials on their products. Visit their web site at www.spiroflow.com for the full details or call them on +44 (0)1200 422525 to discuss your specific requirements.
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