A successful case of customized solution for 1250-type fully automatic diaphragm filter press Project Background
A large enterprise is facing several pain points in the core process of treating the turbid suspension liquid in the first saturation of sugar beet processing, including low filtration efficiency, high moisture content in filter cakes, and poor utilization of raw materials. The existing equipment is not suitable for high-temperature working conditions, has a low degree of automation, and requires high manual intervention, which not only affects the continuity of production but also causes significant production losses. The enterprise urgently needs a complete set of diaphragm filter press equipment that is compatible with the material processing technology, has a high level of automation, and can be seamlessly integrated into the existing system.
Project Requirements
For the filtration scenario of the turbid suspension liquid in the first saturation of sugar beet processing, the customer has put forward comprehensive requirements: the filtration effect should reach the industry's high-quality level, and the consumption of washing water should be strictly controlled; the equipment structure should match the existing installation dimensions, and the core components should be corrosion-resistant and high-temperature resistant, suitable for the material processing conditions; the operation of the filter plates should be fully automated, with a complete cleaning and conveying system, and the control system should be able to be linked to the central controller and reserve interfaces for process upgrades; at the same time, a complete set of equipment, dedicated spare parts packages, as well as commissioning, technical support, and document delivery services throughout the entire process should be provided.
Solution
Tailor-made 1250-type fully automatic diaphragm filter press, fully meeting the high-temperature production process requirements of this material:
Customized equipment body
The main frame of the host is made of high-strength carbon steel with an epoxy-based anti-corrosion coating, ensuring both structural stability and high-temperature adaptability; the filter plates and diaphragms are made of high-temperature resistant polypropylene material, suitable for 1250×1250mm specifications, and achieve efficient dehydration of the material's filter cake through air pressing.
Integrated supporting system
Build a complete set of high-temperature resistant auxiliary systems, with core components made of high-temperature resistant materials, and equipped with frequency converters for precise flow control, meeting the material's conveying and filtration needs; equipped with an automatic cleaning device to ensure efficient maintenance of the filter cloth, and with stainless steel liquid collection trays and protective curtains, ensuring a clean production environment and stable equipment connection.
Highly compatible control system
The control cabinet is coated with a high-temperature resistant anti-corrosion coating, and is equipped with a Siemens SIMATIC S7 controller and a Weintek operation screen, which are seamlessly connected to the central controller through Profinet/Profibus buses, with reserved upgrade interfaces; equipped with high-temperature resistant monitoring instruments and safety devices to achieve real-time monitoring of equipment operation and rapid response to emergencies, ensuring continuous material processing.
Full-process supporting services
Provide a high-temperature resistant dedicated spare parts package; a professional team is responsible for engineering services and full-dimensional debugging of software and hardware, and formulates dedicated operation norms for high-temperature conditions for this material processing; deliver a complete set of technical documents to provide comprehensive support for daily equipment operation and maintenance.
Project achievements
After the equipment was put into use, it perfectly adapted to the high-temperature production process of this material, comprehensively solving the original pain points: all core indicators met the standards, the dry matter content of the filter cake was ≥70%, the residual sugar content, Fₓ index, and wash water consumption were all under control, the raw material utilization rate was significantly increased, and production losses were significantly reduced; the core components were high-temperature and corrosion resistant, and operated stably, the equipment size matched the existing layout, achieving rapid production; the entire process was automated, reducing the operation intensity and cost in the high-temperature workshop, and significantly improving production continuity and material processing efficiency; the control system was deeply integrated with the existing production system, with reserved interfaces to enhance system flexibility; the high-temperature resistant spare parts package and professional services effectively reduced operation and maintenance costs and extended the equipment's service life.
Customer feedback
The enterprise highly recognizes this customized solution, believing that the equipment perfectly meets the high-temperature processing requirements of the first-time saturated turbid suspension in sugar beet processing, and completely resolves various pain points in the original filtration process. Under this material processing condition, the equipment achieves efficiency improvement and cost optimization, providing strong support for the continuous and intelligent upgrading of the enterprise's production. The customer is highly satisfied with the customized design capability, equipment manufacturing quality, and full-process professional services, laying a solid foundation for the in-depth cooperation between both parties in the future.