An Australian manufacturer is helping replace obsolete impact weighers with a simple bolt-in replacement.
Replacing most industrial equipment causes headaches. Often production needs to be paused, and the overall design of the plant might need to be changed – an expensive proposition.
When it comes to impact weighers, things can be even more complicated, as often these important parts of the process are connected to important equipment.
Glenn Jobling, managing director at Flowforce Technologies, said companies around Australia are having a dilemma when Thermo Fisher Ramsey announced it would no longer support the DE 10/20 model impact weigher.
“With support ending, that meant there were only so many years’ worth of spare parts available,” he told ABHR.
“Some businesses decided to make a change, changing to different brands. Others didn’t. Cut and shut works in a plant isn’t quick – it involved a lot of engineering and work.
“At the time, there just wasn’t enough demand to manufacture a replacement. That was until we had an enquiry from a customer with 36 impact weighers that needed replacing.”
FlowForce knew if this South African-based client was in trouble, others in the market would be too. The team soon realised there would be a big market looking for quick replacements when the supply of spare parts ran out.
The company’s engineering and design team got to work to find a solution. The impact weigher had to conform to the footprint of the Ramsey DE 10/20 weighers, while also being easy to install. The solution was the Series 5 impact weigher.
FlowForce’s Series 5 is designed to continuously measure mass flow in mechanical conveying systems, ensuring a smooth material flow without disruption. It is particularly effective in vertical flow streams where traditional weigh feeders or conveyor scales may not be practical.
The system is compatible with a variety of pre-feed devices, including screw or vibratory feeders, belt conveyors, drag conveyors, air slides, or rotary valves. It can handle a diverse range of materials, including fertiliser, fly ash, charcoal, mineral sands, potato chips, and confectionary materials.
Jobling said the unique tool can measure the mass flow rate and total mass of freely flowing particulate materials.
“The Series 5 offers a cost-effective yet highly accurate method for gauging the mass flow of dry solids and powders, making it valuable for inventory process control,” he said.
“We also made sure to include important features that FlowForce had developed. For example, most impact weighers mount the impact plate with the sensing equipment. That leads them into the path of the flow, and if there is any moisture or heat, it can impact the electronics and cause them to fail.
“Around 15 years ago we invented the Magnaflow, which magnetically couples the force impact plate to the force sensing electronics. This magnetic coupling technology improves sensing reliability and removes the sensor from the process path, allowing for high temperature applications and significant impacts.”
Additionally, certain industries need to control the quality and purity of the material being measured. One feature FlowForce has included in the Series 5 is the ability to take real time samples from the flow path for laboratory testing and sampling.
The flow of progress
The Series 5 was designed and prototyped just before COVID-19 caused global chaos. When the borders re-opened, FlowForce was able to install the first of two test units at different sites in South Africa.
Several months later, the customer had replaced all of the DE 10/20 model impact weighers across both sites.
Jobling said the Series 5 had performed so well it grew rapidly in popularity.
“One of the key features is the ability to bolt the Series 5 into the same bolt holes and connections of the DE 10/20,” he said.
“Instead of cutting, welding, and rebuilding connections, you can spend about four hours unbolting the obsolete unit and replacing it.”
Based in South Australia, FlowForce Technologies can support its customers with technical support in person and over the phone.
Spare parts are stored locally at its Adelaide warehouse, with international representatives also maintaining their own supply.
Jobling said the FlowForce team is looking forward to helping customers with the Series 5.
“We really want to let people know there’s an easy solution when it comes to replacing their impact weighers,” he said. “Using the Series 5 minimises downtime and allows plants to be more efficiently run.
“We are also looking overseas to help international clients, too.”