SMB Engineers Marol, Mumbai, Maharashtra

SMB's ROTARY AIRLOCK VALVE’s are designed for various applications, feeding material under high pressure / vacuum with perfect provision of air right scals & uniform discharge from the outlet. It is simplex form of Vane Feeder consists of Airlock Valve Housing, Rotor, Geared Motor, Chain, Sprocket, Chain Guard & Mounting Frame complete. The quantity / flow of material could be adjusted by changing the speed of ROTOR / SPROCKETS. The Rotor blades in pocketed shapes are so perfectly designed that, it handles fine pelverise material, the Rotor is not jammed and also the material is not clogged between the fine gap of the impeller body. The material enters the valve housing from the top & as the Rotor Rotates, each pocket discharges when it reaches the bottom opening of the body.   The clearance between the Rotor blades & Valve Housing is precisely maintained to prevent to prevent the free passage of air between inlet & outlet size of the valve. The RAV’s width NTN FC 207 Bearing of Japan make, are also supplied on request.   SPECIAL FEATURES OF ROTARY AIR LOCK VALVES 1) Body of close grained cast iron or fabricated from M.S. to provide adequate stregth, rigidity and high grade quality of casting.2) Rotor of M.S. / S.S. with shaft ends, machined accurately and mounted on anti-fabrication bearings/ NTN FC Bearings of Japan on request.3) Rotor vane edges machined and fitted with special fibre / SS linings to facilitate close fit between Housing and Rotor which avoids air leakage.4) Rotor speed could be regulated to give rated output as may be required to suit site requirements.5) Various designs of Rotary Air Lock Valve to suit any applications / material.6) Material of Construction: as per requirement.

Most of the factories / Giant Industrial Sheds, handling light Powder Type Material like Sugar, Salt, Milk Powder, Granules, Fibers, etc. are facing serious problems of Dust Pollution. It requires heavy manpower for cleaning floors / machine and this Pollution problem becomes very serious, sometimes causes Fire Casulaties Loss of Human Life requires huge maintenance of Electro-Mechanical machines and equipments. We have designed very scientific, unique Low Cost portable dust collector equipment and solved the very tiresome problems, eliminating the manual cleaning of Floor. It is specifically very useful in Sugar House Cleaning, where the Sugar Dust gets deposited, lot of Sugar falls from Hoppers, Bucket Elevators, Graders, and Bagging Points. The Sugar / Dust needs to be collected frequently. It adds further Dust Problem / Pollution, serious damages to Electricals / Windings, additional man power for maintenance and leads High Risk of Fire, due to dust being highly inflammable. This Unit helps in, faster cleaning of spread or fallen sugar on floor and dust deposits on various equipments. Similarly during Off-season, a series of Electrical Panels / Switch Gears in Power House need high pressure Blower to clean accumulated fine Dust.   Necessary coupling, connections & nozzles are provided for converting the Vacuum Cleaner into high-pressure Jet Blower / Dryer. Hence the utility of this Portable Unit is very well justified.   APPLICATIONS: Industries like  Sugar  Paper Pharmaceuticals  Paint & Pigments  Fertlizer  Cement  Leather  Cosmetics  Agriculture / Seed Processing Ornaments Mfg  Petro-Chemicals  Ceramic: Abrasive Sand, Powder, horts Grit, Metal Powder, Tiles  Food: Sugar, Spices, Tea, Salt, Biscuit, Cattle Feed, Grain, Starch  Chemicals: Caustic Soda, Lime, Detergent, Sunmica, Plywood.

The Problems: 90% Oil & Grease pollution caused due to regular Washing/Cleaning of Mills / Machineries in Plant. Contaminated Effluents contains 100-200 ppm of oil. Pollution Control Board Limit is set 10 ppm maximum. Drains & Gutters are choked with Oil, Grease & Bagasse. Higher BOD Level due to Plugging of Oil layer on pond. Higher Cost of Oil Consumption & Aeration at ETP.   Problem of Oil / Grease Pollution in Effluent: Oil Pollution in effluent, oil - grease contamination is mainly caused due to Washing / Cleaning of Mill/ Machineries in Plant. The escaped Oil & Grease to ETP crosses the maximum permissible limit in the final effluent. Its protective layer in the effluent channel inhibits the exposure of biodegradable effluents to the atmosphere. As a result, the BOD of incoming effluent to ETP is also more than desirable incurring additional cost of aeration. Often, the ETP aeration system in the majority of mills / industries does not operate as desired. Consequently the effluents leaving the factory invariably contains higher ppm of oil and BOD levels higher than permissible. The problem is more serious for the mills, where the effluent/ water is used either for irrigation purpose or discharged in the inland rivers.   I) Oil Skimmer, the Best Solution: To Solve this problem of Oil Pollution right at the source of contamination, we have designed & successfully commissioned Oil Skimmers with especial designed oil catch pits in effluent channel. This method, while controlling the pollution also enables the factory to reuse the recovered Oil, for general lubrication purposes like conveyors rollers; guides; press plates; chain / sprocket gears and weather proofing of spares and also as fuel for boiler firing. More than 100 Factories have installed Oil Skimmers in India. The cost of installation as a result of saving in oil consumption due to recovered oil in 100 days is paid out and at the same time brought down the ppm level below the limits set by CPCB Norms.   II) Latest Design of Oil Skimmer with Refining Unit: To improve the quality of recovered oil, our latest design Oil Skimmer with Refining Unit Model- MOSKMRU, efficiently recovers the escaping oil from the Mill House and refines, restores its original lubricating characteristic, like Viscosity, Density and Index etc. to make it suitable for Lubrication purposes.   Benefits of Oil Skimmer:     1) Helps maintain requirement of water discharge as per Govt. Pollution Control Norms.2) Prevents seizure/plugging of surface / layers / pits / filters / spray pond.3) Reduces Oil content less than 5 ppm in water ? Effluent / ETP final discharge.4) Improves component life by water washing by removing oil deposits / tramp.5) Greatly reduces oil disposal cost and makes reuse of recovered oil for general lubrication purposes / Boiler Fuel / companies reclaiming oil.           Advantages of Oil Skimmers:   1) It lifts and separates oil from pit with any draft without the use of Pumps.2) Negligible maintenance, minimal power and easy to operate.3) Unit efficiently operates in hazardous as well as in turbulence / fluctuating flow of liquid / effluent in drain.4) Special Purpose Designs for Food grains / precious and costly oil are available.5) Indoor / Outdoor Models with Single / 3 Ph Motors, Flame / Non Flame Proof option for hazardous applications are available as per requirement.6) Easy to install, use and maintain without any extra cost, spares and labour.    

The Grit separator works on the principle of cyclonic action. The Solid Liquid Separation takes place due to centrifugal force and difference in densities of grit particles, when the mixture enters the cyclone at pressure. Several Factories have successfully installed our Lime Grit Separator in Super quality heavy duty stainless steel & had taken the advantages of this simple low cost unit. No additional PUMP/ POWER is required as, it is designed to function as INLINE SYSTEM.   The installation of this unit is solving two critical problem in one go, like removal of grit and pH control of condenser water because of routing grit slurry into the spray pond. In addition, this also greatly reduces the sever mechanical damages of pump impellers, juice, heater / evaporator’s tubes, pipelines, valves and filter screens etc. You will appreciate that even this low cost investment is recovered within 30 to 40 days of its installation, due to multifold advantages as explained above.

SMB's DSM/Hydroscreens in loop/welded wedgewire, is developed with new designed enhancements in various models with slit opening sizes from 0.25mm to 2mm and liquid handling capacities ranging between 50 to 250m3/hr. The material standard is 304 SS well as 316 and L Grades are available on request.The Hydroscreen is extensively used in Sugar and Paper Pulp Industries the most effective stationery screen. Its unique screen configuration reduces blinding and also gives an extremely high percentage of open area, allowing maximum throughput and significant reserve capacity over competitive static screens. Description: The screen liquid chamber is technically deisgned to reduce turbulence in liquid slurry and cascades over the weirs, where it distributes flow across the uppermost portion of the screen panel. The solids are retained by the screen, which roll down the curved face, more liquid is removed and allowed to drain freely at the lowest portion of the screen panel.   Salient Features of Screen:   1) Huge quantity of bagacillo removal thereby less load on Juice Heaters/Clarifiers results in the better efficiency.2) Better heat transfer hence substantial savings in steam and also less chemical consumption.3) Improved efficiency of JH/Evaporator /Clarifier Pans, resulting in higher throughput & crushing.4) Savings in lime, sulphur and chemical consumption due to removal of colouring matter.5) Brilliant white, lower ICUMSA quality Sugar due to removal of colouring matter and better quality juice.6) Absence of bagacillo results in less scale formation in JH Tubes, therefore less frequent cleaning of JH.7) Improved utilisation of process equipments, thereby higher crushing possible than the rated capacity of the plant and hence improved productivity.

Fixed type full span structural bridge with platform upto the centre with 1000mm high handrails. High torqueSMB make centre drive with 1 HP motor, Radicon or reputed make gearbox, chain drive, etc., two scraper arms having neoprene squeeges, RPM is 0.08 Center Scraper is provided. Inlet MS tank is hanged from the bridge. All wanted parts are MS epoxy painted and other parts are enamel painted. The scraper arms lifting hand operated mechanism is provided so that in case of overloading the complete assembly can be lifted manually.   The unit would consist of:1) Fixed full bridge with walkway and handrail from one end to centre.2) Influent (feed) well.3) Drive arrangement consisting of motor (Crmpton), gear box (Radicon), pulleys, V-belts, base plate.4) Heavy duty bearing housing to take care of indulations, torque and loads.5) Central shaft.6) Rake arms with blades and tie knots.7) Rake blades in sludge hopper.8) All pipes, including inlet, outlet and sludge pipes are excluded from our scope.

Belt oil skimmer Pollution Control Board Limit is set 10 ppm maximum. Drains & Gutters are choked with Oil, Grease & Bagasse. Higher BOD Level due to Plugging of Oil layer on pond.

The Hydrocyclone based Bagacillo Separator is installed for MJ degritting and crush remival after DSM screen and before weighment for obvious advantages of low cost, high return on investments. Our latest design is very effiecient, economical and designed for capacities 1850 TCD to 10,000 TCD Plants, with complete construction in SS 304/SS 316. Our sophisticated engineering ensures longer life, leak proof operation seasons after season and Nil maintenance by virtue of no moving parts and guaranteed removal of grit and bagacillo from screen juice. PROCESS ADVANTAGES: a) Guaranteed removal of fine grit Bagacillo 10,000 kgs / 100 TCH / Day.b) Bagacillo content in juice not exceeding 1.5 - 2gm / litre.c) Increased efficiency of clarification / JH / Evaporator, hence permitting higher through put.d) Improved recovery of sugar due to less mud volume.e) Less load on Rotary Filter due to reduction in mud volume.f) Less steam consumption due to better heat transfer as less scaling in tubes.g) Less consumption of SO2, lime, viscosity reducer and other chemicals due to less bagacillo in MJ thereby eliminating colouring salts during Juice Boiling.h) Improved Crystallisation in Pans and reduced choking in Centrifuges.   ECONOMIC BENEFITS: 1) Production of sparkling white sugar, additional revenues due to higher selling price.2) Extra revenues of Rs. 5000/- pe day (3000 TCD) on sales of Bagasse, saved from mud.3) Lower production cost due to savings of chemical, steam and less mechanical damages of pumps impellers / screens and less maintenance of machines and equipments.4) Higher sugar production due to sugar saved in press mud.5) Quick payout of full investment in 50 to 60 days of crushing on account of 1 to 4.

Aerators are to installed in Aeration Tank. It is developed by us to suit site conditions through our vast experience in the field of waste water treatment.   The Aerator Cone is designed to lift gently a large volume of waste water, which spurs in the form of heavy torrent over the lip of teh cone on to the liquid surface in the aeration tank. An extremely vigorous wave motion is created outwards over the entire surface. The wave motion greatly increases the area of the liquid surface in contact with the atmospheric oxygen and the oxygen is dissolved quickly and evenly dispersed through the tank by rapid circulation of the liquid.

Type : Fixed surface

Sugar Factories are equipped with bagasse fired boiler, using bagasse with 50-60% moisture. Huge quantity of burnt bagacillo and partially unburnt Fly Ash generated in boilers escapes in the flue gases into open air. The impact of this pollution is quite detrimental to human life. We have designed & installed most efficient Venturi Wet Scrubber which effectively arrests 100% particles of sizes up to 10 micron & bring down the final exhaust emission level within 125 mg / NM. This performance is much below the standard set by Central Pollution Control Board and Significantly no Fly Ash is seen in and around the factory including Township. With this system a serious disposal problem is efficiently solved and hence the area around the chimney is maintained clean and dust free. Our’s is a Pioneer Design, requiring minimum Pressure i.e., < 60 mm, Lowest Power requirement 10 HP / Boiler and Lowest Water make-up. These are the most significant salient features of our System as compared to any other Designs available in India or abroad.

Almost every second factory is facing serious Sugar Dust Problem, resulting in coating of dust on sugar grain due to presence of fine dust in bagging. More over the spreading of dust in Drier/Sugar hous eis not only causing serious Dust Pollution but also a sheer loss of product due to dust generated in sugar handling. The system arrest the Fine & Flying Dust, generated during drying, conveying, sizing, bagging & ensure the work area clean, free from dust build up eliminates the risk of fire and Mechanical/Electrical damages otherwise take place due to dust emission. The dust so recovered is recycled and yields additional recovery. Dust collection is a continuous and on-line process in which specially designed suction hoods are placed close to the generation of dust. The exhaust extracted by the suction hood is carried to a separation device Wet Scrubber above, through a network of ducting, finally disposed off by mixing it in recirculating water. We have successfully solved the Dust Problem as well as improved the Luster Quality of Sugar in 40 Factories.and enjoying the TREMENDOUS BENEFITS of installations. The average dust collected in almost all factories is found 125 kgs. on every 1000 quintals of sugar produced / bagged in Sugar House. We are the only top dust collector manufacturer giving the best machinery with the below features. SALIENT FEATURES OF SMB’s VENTURI TYPE SUGAR DUST COLLECTION SYSTEM: 1) High Efficiency dust collection system effectively arrest particles up to 5 micron.2) Hoods & entry to Dust collector is designed to eliminate entrainment of dust.3) Ventury type Cyclonic Wet Scrubbers are almost ideal for large amount of abrasive fine dust.4) Complete Remedy for sparks / risks of fire, frequent damages of Electricals & bearings.5) Almost 100% collection of Flying Dust, Cooling effect at Pan Station & comfortable climate.6) The State-of-the-Art Technology, Computerized Design for Scrubber & Fan for Durability & smooth performance.7) Four Important Tasks Working, Environment, Economy, Seasonal returns & Negligible Maintenance are being considered for System Design..

Sugar Factories are equipped with bagasse fired boiler, using bagasse with 50-60% moisture. Huge quantity of burnt bagacillo and partially unburnt Fly Ash generated in boilers escapes in the flue gases into open air. The impact of this pollution is quite detrimental to human life and could cause significant damage to the environment. Hence the govt. is seriously implementing pollution norm.   Mechanical multicyclone type dust collector is designed for reliable services with minimum maintenance. They are simplest economically designs having wide range of applications. The operating principle of the AIR Multicyclone Collector is cyclonic action. Dust laden air / gas enters top of the precipitating cells at inlet ramps which directs the gas into a spiral flow. Centrifugal force causes the dust to separate from the gas. The dust is forced against the wall of cells into closed hopper. The cleaned gas is pushed through outer tube placed at the top of precipitating cells. The mulitcyclone has no moving parts. It is comprised of numbers of cells of suitable diameter depending on the desired efficiency and the application requirements.

SMB’s Computer aided Hi-tech designed Centrifugal Fans are available in Backward Curved Type, Radial Blade Type and High Pressure Types.Industrial Centrifugal Fans Backward Curved fans are used for high capacity up to 170,000 m3/hr. low pressure for Ventilation. Air conditioning Induced Draft Dust Loading and Dust Collection. Radial Blade Fans are used for Medium capacity. Up to 2000 WG are used for Low capacity for material handling for Oil Furnace, Fume Extraction, Pneumatic and Aeration. Our Hi-Tech Computer aided Design; High Efficiency Centrifugal Fans are available in Backward Curved Type, Radial Blade Type and High Pressure Type. Backward Curved fans are used for high capacity (up to 1, 70,000 m/hr) induced Draft Dust Loading & Dust Collection & low pressure Ventilation Air Conditioning. Radial Blade design is suitable for Medium Capacity (up to 50, 000 m/hr). Medium Pressure (up to 2000 mm WG) Fans are used for low capacity material handling, Oil Furnace; fume Extraction, Pneumatic and Aeration purposes. Special Designs & MOC as per clients’ requirement can also be supplied. All our fans are statically dynamically balanced & tested for smooth, trouble free performance. Salient Features of ID FD SA Fans Computerized high efficiency low power consumption (20% less power assured than old design) Single ID Fan of 125 HP Motr on ID fan upto 25 TPH Boiler Capacities upto 2 lacs m3/Hr Hot & Cold Blowers for sugar drying for 10-40 Tons/Hr Bagacillo Transfer Blower with cyclone for mud filter station Ventilation System for power house, no need of AC’s in panel room HD Industrial portable dust collector for sugar house in season & also used as vacuum clearner in power house / electrical panel for cleaning in off-season.

SMB's magnets have carved out an unique place for itself at the forefront of magnet technology with a reputation for the highest quality standards reliability. MAGNETS: are very hard, but more brittle and more prone to cracks and chipping on the edges / corners. They are characterised a very high normal and intensive coercive force, but, rather low residual induction and are virtually free from self-Demagnetisation. They possess a very high electrical resistivity which makes them ideally suited for high frequency applications. The shapes of magnets available are Rings, Rectangulars, Strips, Squares, Segments, Disc, Cylindricals, Plastro-Ferrite Strips, etc.   Grill Type: These Types Units could be easily installed at Bucket Elevator inlet, Bin Top, Grader Chutes where the sugar passes down the grills. The Magnet bars rotate in Grill Unit, could be easily removed individually by plugging out or in, could be cleaned & again placed in position with minimal loss of time. Drawer Type for Grader: It is conveniently installed at Sugar discharging Chute of Grader or at Bagging Point. The hooks for holding the bags are provided. The magnets are placed inside the SS pipes & are commonly attached by strip with handle to form like drawer. The drawer is taken out to demagnetize the system, for removal of iron particles. Rail Type for Sugar Hopper: The unit is installed inside the side walls of Sugar Hopper. The magnet face is placed towards the flow of Sugar Blanket to arrest the fine iron particles from the passing Sugar. The SS thin sheet or Jali cover (shielding on magnet sides) is provided to protect the direct sticking of iron particles to the Magnets System. Hose shoe / U Magnet for Sugar Grader: This are available in various sizes and capacity and is the most handy device for separating Iron from non-ferrous scrap, plastic or any other material. These are available in various sizes 50 to 100 mm W, 60 to 100 mm L & 50 to 75 mm H. Pulley / Drum Type for Sugar House: The magnetic drum pulley consists of SS outer drum, hollow shaft, Magnetic Disc (angular 300 deg./Full), placed between MS disc, Central Shaft, Bearing Blocks, V Belt, Geared motor, Mounting Brackets with Pedestal etc. The outer drum over stationery motor magnet driven by gear motor. The truncated magnet (inside), in outer drum assembly, is cut axially 60 deg., which acts as de-magnetizing zone. It results in quick removal of arrested iron material on rotating drum. Pulley with 360° magnet is also available. SMB’s Magnetic Trap / Device (Dry / Wet) for Mixed Juice Lines (JH/EV.) Juice Heater, Evaporators, Water Pipe Flow: SMB's Magnetic Trap is a very scientific device placed in Juice / Water Pipe Lines to control scales in tubes in Juice evaporators / JH. There various sizes but 4”, 6”, / 8” are commonly used. After the installation, the Scales formation is minimized & becomes very soft. It is very easy to remove & clean the Iron Particles arrested on the Higher Power Mono-Pole Magnets & can be placed again for Operation. The other applications are in Distillation Column, Boiler Feed Water, and Turbine Cooling Water & Other Lines. The Installation saves consumption of Anti-Scalent, Softener, Reaming Tools, and Repair & Maintenance Time Less No. of Cleanings (due to less scales formation). It is one time installation & does not require any power. Magnetic Plates: Permanent Magnetic Plates are used for separation of tramp iron found in Tea, tobacco, Coffee, Cocoa, Milk Powder, Sugar, Chemicals, etc. They are available in both flat and curved shapes and could be installed either above or along the passage of materials flow. Ferrite Ring Magnets: It is circular washer type Ring magnets available in OD from 30 to 150mm and ID 15 to 60 mm and widths 5mm to 20mm. Ferrite Cut / Bar Magnets: It is Rectangular Bar Magnets available in 10 to 150mm length, 10 to 25mm height and 5 to 25mm width. It is also supplied in strips / bars as per requirement. Magnetic Chcks (Round/Rectangular): It is available in isotropic material which do not have any specific directions, they can be magnetised by any one of the 3 axes. Isotropic Disc magnets are avilable from 4mm to 50mm diameter and their varying heights.  

Sugar : Mixed / Screened Juice, OC Filtrate, Melt, Seed, MOL, Syrup & Sugar, Grading, Fly Ash.Paper & Pulp : Fiber Recovery, Black Liquor, Milk of Lime & Coating, Chemical Additives Preparation Plant.Ceramic : Abrasive, Sand & Glass, Ceramic Slip, Glazed Section, Ceramic Powder, Insulator Slip, Metal Powder / Shots & Grits.Food : Biscuit, Edible Oil, Cellulose Powder Cattle Feed, Starch Slurry, Spices, Tea, Table Salt.Pharmaceuticals : Aspirin, Bulk Drugs, Calcined Petroleum Coke, Detergent Powder, Fertilizers, Paints, Sulphur Powder, Sodium Sulphate. Salient Features of Vibro Screen: A Serious problem of fine floating bagacillo in screend juice, clear juice, syrup, sugar melt and frit in lime slurry nicely solved. Due to bagacillo removal; less load on juice heaters / Clarifiers results in better efficiency Better heat transfer hence substantial savings of steam Less chemical consumption Improved efficiency of JH / Evaporator / Clarifier Pans & higher throughout & crushing Saving in lime, sulphur & chemical consumption Better quality juice. Brilliant white, lower ICUMSA quality sugar Less scale formation in JH Tubes, therefor less frequent cleaning of JH. Dust Cover for Vibro Screen: Dust Cover assembly comprises cover, packing ring with neoprene gasket and clamp set. Dust cover is having 2 inspection windows and one centre feeding opening. Feed Tray for Vibro Screen: It is used when number of screens are more than one. It is provided below the upper screens so that the material is centrally fed from top screen to bottom screen. SMB’s Clean Screen Rings Tray: It prevents screen blinding by fibrous, stingy and sticky material. The mulitplane inertial vibration combined to create shearing actions which cut the fibres and scrap away the gummy / clogged material. SMB’s Spray Header & Nozzles for Screen Washing: These perforated, ball shaped, stainless steel spray nozzles, provide multi directional spraying of cleaning and rising fluids, simplifying the cleaning of circular separator interiors. The on-line cleaning helps to maintain screen clean, free from gums and wax deposits. Ball Tray (Anti Binding System): The balls continuosly vibrates, the impact of the balls flexes the operating screens, dislogging near size particles to keep the screen clean. The ball tray can be fixed / removed as may be required. Rugged Reliable Economical Choke Free Most Efficient Screens

Concept: The SMB's Rotoshear Rotary Screen is a high caapcity fine wedgewire screen that is developed with new design enhancements in various models with slot opening sizes from 0.25-1.5mm and hydraulic capacities 100-500 m3/hr. The material standard is 304 stainless, but 316 and L grades are available as well. Wedgewire Construction: The Rotary Screen is made of 304 SS wedgewire, recognised for its ability to handle stringy fibres, greasy solids and high concentrations of suspended solids without blinding. The entire screen cylinder is surrounded by stainless ribs of size of headbox to cylinder length which creates a drying zone to allow free drainage of screening as they travel along to discharge. Salient Features of SMB's Rotoshears Rotary Juice Screen:     1) Huge quantity of bagacillo removal thereby less load on Juice Heaters / Clarifiers results in better efficiency.2) Better heat transfer hence substantial savings in steam and also less chemical consumption.3) Improved efficiency of JH/Evaporator /Clarifier Pans, resulting in higher throughput & crushing.4) Savings in lime, sulphur and chemical consumption due to removal of colouring matter.5) Brilliant white, lower ICUMSA quality Sugar due to removal of colouring matter and better quality juice.6) Absence of bagacillo results in less scale formation in JH Tubes, therefore less frequent cleaning of JH.7) Improved utilisation of process equipments, thereby higher crushing possible than the rated capacity of the plant and hence improved productivity.