SOLUTIONS

AGGREGATES

Dedust 200 mesh

For most quarries, wet washing is an all too familiar method of removing 200 mesh fines from crushed stone screenings. Using water to separate fines is expensive and settling ponds require lots of land with added expenses.

Sturtevant’s Solution: Air Classifiers The Sturtevant Whirlwind Air Classifier provides the aggregate industry with an alternative to wet washing minus 200 mesh fines from crushed stone. Quarries can have a usable product and aren’t saddled with wet fines that have to be recovered from settling ponds or disposal costs.Air classification provides the most effective means for separating a product from a feed stream, for dedusting. The Whirlwind recycles nearly all of the working airflow and does not require a cyclone or baghouse to recover the fines.

Sturtevant’s Solution: Air Classifiers

The Sturtevant Whirlwind Air Classifier provides the aggregate industry with an alternative to wet washing minus 200 mesh fines from crushed stone. Quarries can have a usable product and aren’t saddled with wet fines that have to be recovered from settling ponds or disposal costs.Air classification provides the most effective means for separating a product from a feed stream, for dedusting. The Whirlwind recycles nearly all of the working airflow and does not require a cyclone or baghouse to recover the fines.

. The Whirlwind Air Classifier offers a dry dedusting alternative with several advantages

Minimal land requirements – No settling ponds or land restoration
Water conservation – No water required
Saves operating expenses – Low energy consumption
Lowest capital cost – No auxiliary equipment is needed, such as baghouse, screen, cyclones, process dust collectors, air locks, and system fans
Fines removed from the crushed stone are dry and can yield profits when sold for aglime or filler in various markets

Aggregate Applications:

Limestone, diabase, gabbro, granite, trap rock, sandstone, basalt, sand and gravel, calcium carbonate, silica, feldspar, fly ash, kaolin clay, iron ore, diatomaceous earth and coal.

ANIMAL FEED PROCESSING

Animal By-Products – Double Your Profits

Proper pet nutrition is important to pet owners in the selection of their pet foods and pet manufacturers want to deliver better pet foods to meet customer demands. As a result, renderers and animal protein companies convert animal by-products into value-added feed ingredients and create superior products at competitive prices. To do so, they need to develop high-protein, low ash feed ingredients that are highly-digestible.

The Whirlwind Air Classifier has successfully processed many animal feed materials including:

Poultry & Chicken meal
Lamb Meat & Bone Meal
Porcine/Pork Meat & Bone Meal
Fish Meal
Bovine/Beef Meat & Bone Meal
Duck Meal

Sturtevant’s Solution: Whirlwind Air Classifiers – Animal Feed Processing:

Capability to process an extensive range of dry materials
Higher capacity and finer separations than screeners
Simple construction, low maintenance, easy-to-use controls
Dial-in external fineness controls: no system shutdown to change products
Maximized wear-resistance for abrasive materials in special applications
Easily modified for air cooling or drying of product
Safe classification for heat-sensitive materials
No screens to wear, block, or tear

CHEMICAL MANUFACTURING

Perfecting Control of Particle Size:

Chemicals are air classified according to size or density. Air classification provides the most effective means for separating a product from a feed stream, for dedusting, or when used in conjunction with grinding equipment for increasing productivity.

The Micronizer and Air Classifier have successfully processed many chemicals including:

The Whirlwind Air Classifier offers an exceptional ability to separate poultry meal and other animal feeds into products with higher protein, higher mineral and reduced ash content. When animal feed meals made from poultry by-products are classified, the protein content can be increased thereby providing value added materials needed. The air classified coarse product with regular ash is used as the main poultry meal feed for chickens. The Whirlwind Air Classifier features and benefits include:

Agricultural chemicals
Epoxy powder coatings
Magnesium hydroxide
Pharmaceuticals
Cosmetics
Pigments
Propellants

Sturtevant’s Solutions: Air Classifiers, Micronizer, FCM, Simpactor

Air classification provides the most effective means for separating a product from a feed stream, and can help with dedusting, or when used in conjunction with grinding equipment can result in increased productivity of the chemical. Jet mills and Air Classifier Mills are used in various degrees of impact and agitation and can help reduce and control the size and shape of chemical materials. Pin mills can also help reduce chemical particle size and increase the surface area, making the chemical more effective.

Cosmetics

Griding / Milling Cosmetics Powders

The Steam Micronizer® by Sturtevant is a jet mill that grinds and classifies cosmetic powders to low and sub-micron particle sizes in a single operation using high pressure air, gas or steam to induce particle-on-particle impact reduction.

Talc
Pigments
Titanium dioxide
Hydrated lime
Calcium carbonate
Blushes

Eye shadows
Mica
Lipsticks
Gem stones
Walnut shell flou

Sturtevant’s Solution: Steam Micronizer

Mills cosmetics in a continuous process – no more batches
Greater coverage, consistent color uniformity, opacity and gloss
No oversize grit
Easy to clean with complete access to the internal grinding chamber
No heat build up
Product contact parts can be made from stainless steel, aluminum oxide and tungsten carbide to provide protection against wear and contamination
Laboratory, pilot plant and continuous production models are available

FLY ASH BENEFICIATION

Reduce LOI Carbon Content

Sturtevant’s Solution: Fly Ash Air Classification

Sturtevant Air Classifiers are able to control the fineness of fly ash by air separating it at 200-325 mesh (75-45 microns), thereby reducing the LOI carbon content by 50% or more to a level that is appropriate for use in cement, as a filler for land reclamation, soil improvement, lightweight aggregates, and agricultural uses.

Three Sturtevant Models are available to meet a variety of needs:

FOOD PROCESSING

USDA Design Milling for High Quality Food Ingredients

The Simpactor FID Mill and FCM Air Classifying Impact Mill are the perfect solution for milling and separating dry powder food ingredients. The Simpactor FID Series are specifically designed FDA/USDA type mills that can save up to 50% of the capital cost.

The Simpactor FID Pin Mill and FCM Air Classifying Impact Mill have successfully processed many dry powder food ingredients including

Corn flour
Pea flour
Corn meal
Soy proteins
Preservatives
Flavor enhancers
Fat replacements
Nutrients

Grains
Root starches
Sugars
Sweeteners
De-hulled rice
Wheat flour
Emulsifiers
Stabilizers

Thickeners
Leavening agents
Yeast nutrients
Dough strengtheners

Sturtevant’s Solutions: Simpactor FID Series and the FCM Classifier Mill

Minimize material build up and food contamination
Allow for quick access to clean for minimal downtime
Maximum wear protection, lower maintenance

Infestation Destruction
The grain and milling industry uses chemical fumigation to kill insects, eggs and larvae in its plants. Methyl Bromide is typically used for infestation control, but it will soon be banned by environmental agencies. The alternative chemical, Prophium Sulphonla is more expensive and is still unsafe. Many millers are producing organic products in which chemical infestation control cannot be used.

Surtevant’s Solution: Infestroyer

Guaranteed 100% kill of infestation
Eliminate chemical fumigants: average ROI of 9 months
Easy set up and operation: adjust process while operating
Gravity or blow through processes without space consuming auxiliary equipment
SQF Safe Quality Food Certification

Infestroyer has successfully destroyed infestation in many dry food ingredients including:

Wheat and Corn Flour
Bakery Mixes
Corn Meal
Semolina

LITHIUM CARBONATE

Air Classification, Compaction and Milling of Lithium Compounds for Battery Applications

Sturtevant’s Lithium Carbonate Processing Solution:

The drying of lithium produces excess fines, if the percentage of fines is 20% or greater, then pre-classification is needed. The SuperFine Air Classifier can successfully remove 30-40% of the lithium powder as battery grade product prior to milling. Only 60-70% of the lithium feed needs to be compacted and milled due to pre-classifying.

PHARMACEUTICALS

Produce Superior API’s and Excipients

Manufacturers of active pharmaceutical ingredients are looking to reduce materials to a uniform particle size to increase the surface area which enhances dissolution and the bio-availability of a drug. The rate of dissolution of a tablet or capsule is crucial and inadequacies in bio availability can mean that the ingredients are ineffective or worse, potentially dangerous, leading to toxic overdose. While milling APIs and excipients, it is also important to avoid degradation and change in polymorphic form caused by excessive heat generation.

The Pharmaceutical Micronizer has successfully processed many pharmaceutical ingredients including:

Oral powders
Injectables
Inhalation powders
Topical powders
Excipients
Vitamin compounds

Cell cultured powders
Amino acid powders
Enzyme powders
Peptide powders
Lactose

Sturtevant’s Solution: Pharmaceutical Micronizer® The Pharmaceutical Micronizer’s Open Manifold Design allows complete access to the internal material grinding chamber and compressed air chamber for easy cleaning, product changeover or inspection. The Pharmaceutical Micronizer has no moving parts, no jet nozzles and has quick release clamps for easy disassembly by hand without tools.

Mill to Low Micron particle sizes
Spherical uniform particle shape
Better control properties
Narrow size distribution
No heat or contamination

Pharmaceutical Micronizer® Features

Documentation to support FDA validation
Sanitary design requires no tools – disassembles by hand
Accessibility to all internal areas for easy washing, autoclaving or swabbing
Consistent control adjustments for repeatability
Fluid filled gauges pre-calibrated for easier validatio

PIGMENTS

Consistent Color Uniformity of Pigments

Key characteristics of pigments include color, particle size, refractive index and the delivery form. Dispersion and deagglomeration are important aspects of milling pigments. Processing to fine particle sizes, with uniform surface area for consistent color uniformity are also vital aspects of processing pigments.by Sturtevant is a steam or hot air powered machine, ideally suited for inorganic pigment powders like Titanium Dioxide (TiO2), with no moving parts, used to either reduce particle size or deagglomerate at rates up to 4 tons per hour.
by Sturtevant is a steam or hot air powered machine, ideally suited for inorganic pigment powders like Titanium Dioxide (TiO2), with no moving parts, used to either reduce particle size or deagglomerate at rates up to 4 tons per hour.

Sturtevant’s Solution: Whirlwind Air Classifiers – Animal Feed Processing

Mills pigments in a continuous process – no more batches
Greater coverage
Increased gloss and opacity
Consistent color uniformity
No oversize grit
Increased surface area

Tighter PSD
Uniform size, spherical shape
Better control properties of powders (suspension, dispersion & absorption)
Complete access to the internal grinding chamber for easy cleaning
No heat build up

The Steam Micronizer has successfully processed many pigment powders including:

TiO2
Carbon black
Iron oxide
Clay
Epoxy powder coatings

Ceramics
Resin
Toner
Organic and inorganic pigment and ink powders

Sturtevant’s Solution: Steam Micronizer

The benefits of using the Steam Micronizer by Sturtevant for processing pigments include:

Poultry & Chicken meal
Lamb Meat & Bone Meal
Porcine/Pork Meat & Bone Meal
Fish Meal
Bovine/Beef Meat & Bone Meal
Duck Meal