by Jasper Consulting | Sep 4, 2020 | News
AFX has over 30 years' experience in the field of mixing technology. We have a broad range of quality process mixing systems and agitators to suit various industrial applications and provide solutions to all your manufacturing requirements.
On our larger agitators, gearboxes are designed to incorporate a dry well and heavy-duty output bearings. In the majority of instances, we also allow for an extended bearing distance. Normally, gearboxes are selected on torque alone, but with agitators, the overhung load is large, and the drive is subjected to high external loads. Our selection, therefore, doesn't only cater for the transmission of power, but also its ability to withstand external forces.
With tanks being larger, the structures the agitator needs to mount onto becomes more susceptible to inaccuracies and misalignment. With the intention of saving costs, many manufacturers allow their gearboxes to be bolted directly onto faulty beam structures. By mounting a machined gearbox directly onto a fabricated structure, it preloads the housing. This causes additional stress within the housing itself. During operation, this misalignment, combined with any twisting of the beams, will cause premature casing failure. AFX-designed gearbox bases have machine mounting surfaces that don't need shimming and won't preload the gearbox casing. Bases are designed to withstand much greater loads than what the agitator is subjected to. This enables the base to increase the rigidity of the structure.
Our range of portable top entry mixers suited to smaller mixing and blending applications provides the customer with the freedom to decide how to mount, move or permanently fix the agitator. Portable air or direct drive units are supplied with swivel brackets perfect for mounting at the desired angle. Some small direct and gear drive units can be wall mounted for applications with multiple containers. Angular mounted or angular offset agitators are commonly employed for use in cylindrical mixing vessels which are un-baffled. The portability of our small agitators gives good flexibility, allowing freedom to move from one vessel to another. Our applications engineers are on hand to advise the most suitable configuration for your needs, to ensure these versatile agitators offer the user the most economic mixing solution.
Through our team of highly experienced field service engineers and technicians, we can offer clients a range of training options to suit their specific needs. Whether you are looking to provide personnel with basic operation training, product maintenance training or a complex understanding of the equipment and associated process design we can help.
We can provide:
Based at the new AFROMIX facility in 25a Rudo Nell Road, Jet Park, Johannesburg, our new service team is staffed by highly qualified and experienced engineers. All work is completed to ISO 9001:2015 accreditation and is CE certified. Service provided by AFX will provide the most cost-effective solution with regards to the price of spare parts and labour against the cost of new equipment.
REPAIR AND REFURBISHMENT
AFX offers a comprehensive repair and refurbishment service for your mixing and pumping equipment, including an on-site hose replacement service for both our own and 3rd party peristaltic hose pumps. Quality is assured with all repairs being completed with original, or where unavailable, high quality remanufactured parts. The AFX group also manufactures its own range of mixing and pumping equipment, and can offer cost-effective replacements of old or obsolete equipment that is beyond economical repair.
PREVENTATIVE AND CONTRACT MAINTENANCE PROGRAMMES
AFX can recommend a maintenance scheme to suit your individual needs:
AFX can provide regular inspections on most installations and can tailor the service to meet your needs, giving your plant a longer working life and help increase your return on investment. The AFX service team operates worldwide and can provide a wide range of servicing either within our own service centre or on-site at a client’s premises.
DIAGNOSTIC, PERFORMANCE AND HYDROSTATIC TESTING AND INSPECTION
At our Jet Park service centre, we have the facility for calibrated testing of new and repaired mixing and pumping equipment.
Site surveys can be conducted to ensure you have the correct mixing or pumping solution in the short, medium and long-term:
DESIGN, INSTALLATION AND COMMISSIONING OF MIXING AND PUMP SYSTEMS
The AFX team can supply and install your complete mixing and pumping systems:
We can also work to design, specify and retro-fit enhanced mixer and pump solutions into an existing system.
The AFX Group of companies continues to grow and reinforce its reputation as an industry leader in the field of mixing, agitation and peristaltic pumping. With this growth comes the opportunity to partner with like-minded dynamic companies who can represent our world-class products. We are looking for quality, motivated organisations that can represent us in our core industries including:
All our dealers receive comprehensive training and support tailored to their individual needs. We believe in true long-term partner relationships that will benefit all parties.
If you feel that you have what it takes to partner with a forward-thinking, dynamic company offering world-class products, then we would love to hear from you.
For further information, please contact Nadine Brockman on 27 (0)11 397 6911, or send an email to email@example.com.
Our extensive range of peristaltic hose pumps includes one of the largest pumps of this type in the world. Our 150mm pump has a maximum flow rate of 147m³/hr and can deliver pressures up to 10 Bar. These units are ideal for thickener underflow applications.
AFX also supply hoses for many makes of peristaltic pumps and has the expertise to advise on all piping and system layouts.
AFX PUMP SERIES
The AFX Peristaltic pump range has been designed to be a robust pumping solution for high viscosity, high solids (abrasive), high density slurries and liquids for a wide array of applications and industries including mining, chemical, food and beverage, pulp and paper, petrochemical, pharmaceutical, agricultural, water treatment and many more. Building on a proven concept our latest development is the AFX PUMP SERIES which was specially adapted to further improve the product’s high performance, durability and low maintenance.
All AFX’s products are designed to deliver exceptional performance, but what sets this pump apart from its competitors is its cost-effectiveness and reliable operation. AFX can demonstrate measurable savings when using the AFX PUMP over that of its competitors, including energy savings and maintenance downtime savings of up to 50% compared to traditional peristaltic hose pumps. The pumps are self-priming, fully reversible, highly durable, easy to maintain, can be run dry for extended periods without damage, and offer flow rates from 40 l/hr to 150 000 l/hr.
The internal workings of each pump comprise of a rotor block with solid rotating rollers. The pumping action results from alternately compressing and relaxing a specially designed high-pressure peristaltic hose between the pump housing and the pump compression rollers to create an airtight pocket. The fluid is pushed along the hose towards the discharge by the compression rollers, creating a positive displacement. The reopening hose behind the roller draws more fluid into the pump through the suction. Due to this method of operation where there is 100% hose closure at all time, the pump is on its own a non-return mechanism. This ensures excellent metering accuracy and reduces the need for additional equipment downstream.
The AFX PUMP SERIES are commonly used in applications where the product to be pumped has a high solids content and/ or viscosity, such as thickener underflow, slurry transfer and chemical transfer or dosing applications; but are popular solutions for many other applications which include:
Boasting eleven AFX peristaltic pump models with flow rates between 40 l/hr to 150 000 l/hr across the range the AFX PUMP SERIES have become industry favourites across many countries. We attach the same care and dedication not only to pump and hose design but also to the selection and application of our pumps. To ensure optimum performance and product life, as well as to minimise operational cost and maintenance downtime, every AFX pump is carefully selected, configured and equipped for a specific application’s requirements by an experienced application specialist.
We have a high level of expertise in mixing processes and mechanical design that can provide innovative solutions from fresh angles. No matter the make or type of mixer, our systematic approach from our highly-experienced engineers, can determine if improvements can be made in your plant. Mixer studies range from basic audits and plant surveys, to complete troubleshooting programs. Working in close association with your plant personnel, data is collected and processed in our simulation package to pinpoint any weaknesses in the existing design. We will provide you with a detailed report of our findings with any future recommendations.
Optimising plant operations can considerably increase your profits. It is not unusual for payback times to be measured in just weeks or months. Any improvement in product recovery or quality, with minimum capital outlay, results in additional revenue that directly increases profit.
The following situations are examples of where our audits have led to identifiable improvements:
As specialists in the field of peristaltic hose pumps, we have a high level of expertise that can often highlight simple yet highly cost-effective changes. No matter the make or type of the peristaltic hose pump, our systematic approach from our highly-experienced engineers can determine if improvements can be made to your system. Pump studies range from basic audits and system surveys to complete troubleshooting programs. Working in close association with your plant personnel, data is collected and processed through our own bespoke in-house design and pump sizing package to pinpoint any shortfalls in the existing system and pump setup. We will provide you with a detailed report of our findings with any future recommendations.
Optimising even small parts of the plant can often considerably increase profits. It is not unusual for payback times from our recommendations to be measured in just months. Any reduction in operational and maintenance costs or process improvements can result in additional revenue that directly increases profit.
The following situations are examples of where our audits have led to identifiable improvements:
To eliminate potential design errors, AFX ensures that all its manufacturing drawings are produced in 3D. A process referred to as Finite Element Analysis (FEA) is used in instances where large, or infrequent components are designed. The analysis combines all the operating loads of the system, allowing the designer to see potential flaws before manufacturing takes place.
Mounting bases must accommodate machined gearbox bases and fabricated beam structures and prevent twisting and stressing of gearbox casings – a common cause of failure of proprietary drivers.
Bearing members often house mechanical seals or serve to isolate the gearbox from high bending moments. Accurate prediction of stress, movement and deflection are critical.
AFX makes use of Finite Element Analysis (FEA) for its designs allowing its engineers to model the combination of loads applied to the actual components resulting from the impeller’s rotation system and its interaction with fluids and slurries. By making use of this method, the applied bending moment, torque and thrust can be predicted and adequately accommodated in the design. Detailed FEA is required in instances where important components carry critical loading. Shown below are some examples of our FEA applications.
Computational Fluid Dynamics (CFD) is the method of applied mathematics, physics and computational software used to visualise how a gas or liquid flows, as well as how a gas or liquid affects certain objects as it flows past. AFX makes use of CFD in numerous applications to calibrate flow numbers, view velocity vectors and assist with solving process problems.
Agitator shafts are manufactured to a stringent straightness tolerance of 1mm/metre of shaft length.
We manufacture various types of impellers for different applications, including high viscosity blending.
Mounting bases are critical components in ensuring that the gearboxes are correctly aligned and mounted to the beams or structure.
These independent units are designed to accommodate all the loads and forces applied as a result of the mixing action.
Our pumps are at the forefront of peristaltic pumping technology. Developed to handle near impossible pumping applications, the AFX series pumps have become industry favourites.
As the name suggests, these agitators are directly powered by the installed motor. Being a very cost-effective and quick agitator to supply, there are many small and easy blending applications where direct drive agitators are well suited. Using our range of F3 axial flow impellers, the agitator delivers on the process requirements. Most commonly used in small pilot and bench plants, pharmaceutical laboratories, test laboratories in research and development departments as well as in batch development within the personal care industry, these direct drives are adaptable, easy to use, require little maintenance and ensure that the desired process outcomes are met. Available with variable speed drives and various mountings, we are certain that we will meet your process solution.
As all mixing and blending applications differ, the demands placed on the agitator do too. In some applications, the use of a direct drive is just not possible for various mechanical reasons. Keeping this in mind, we offer small portable gear driven agitators. Sizing the agitator to suit your vessel as well as to ensure that the desired process is achieved, we strive to bring you the best top entry solutions. Tailoring our manufacturing methods, we can keep costs competitive and guarantee the best quality agitator. The majority of these units can be found in applications where a solid suspension is required, or the viscosity of the product is high within the vessels or where the mixing application is arduous. These agitators power a large segment of the market, where the demand has not waivered. Available with a selection of various options to ensure that the agitator is customised to suit your specific needs and process requirements, our range of AMX portables are a solution within the various markets, and they continue to expand their application reach.
AFX offers small electric or pneumatic agitators perfectly suited to small instant blending applications in 210-litre drums, where flash mixing and blending is required. Although designed primarily for 210-litre drums, these adaptable mixers can be easily adjusted to suit smaller containers by changing the shaft length. Two standard designs are available to suit both open and closed top drums. For closed top drums, agitators are supplied with a dual bladed folding impeller designed to fit through the bung hole on the top of the closed drum. The agitator comes complete with a threaded bung hole adaptor for mounting and operating purposes. For open top drums, agitators are usually supplied with our fixed three bladed F3 impellers. These units are cost-effective, efficient, easy to operate and maintain. Their portable design allows the freedom to move from one vessel to another. Operating between 300 – 3000 rpm. The wetted parts are manufactured from stainless steel and the aluminium housing aids the light-weight design of this agitator. These agitators are the number one solution for light drum mixing and blending applications.
AFX offers a range of Intermediate Bulk Container (IBC) mixers (also known as TOTE or flow bin mixers) specifically designed to handle mixing duties within the container. Our mixers handle varying ranges of viscosity, densities and other processing requirements. The main feature of AFX’s design is found in a range of folding impellers. These impellers are based on our range of high-efficiency hydrofoils that can fold in to facilitate fitting through the limited container opening, without the need for any modification to the container. The container openings vary from 100mm (4″) up to 200mm (8″). Our stainless steel impellers are available in varying diameters from 132mm (5,2″) up to 435mm (17,1″) which allows us to meet most application requirements. With the impeller being a hydrofoil the design offers the efficiencies of a fixed bladed impeller system. Our design results in lower power consumption compared to our competitors while maintaining the same results. This improves the process efficiencies and reduces the mechanical loading on the agitator. This reduced mechanical loading allows the agitator to be lightweight and durable.
TOP ENTRY MIXERS
The need for larger mixers has increased in recent years, mainly due to the industry’s requirement to expand operations, or to keep production costs as low as possible. At AFX, we customise our top entry mixers to accommodate your process. Our top entry mixers are available in different technical specifications and can be used for specific purposes across different industries. In the past, large top entry units were more commonplace in the mining industry. However, this trend is now changing with other industries now also requesting larger and more specialised mixers.
As agitators become larger, the loading requirements increase considerably, and every component is looked at individually, ensuring it is robust enough to handle the application. At AFX, all design work is further scrutinised using Finite Element Analysis (FEA) to ensure that failures do not occur. Many companies tend only to use FEA’s once they have experienced problems or failures. We use FEA’s and our design know-how to avoid problems before they happen.
Components are isolated and designed to handle loads far more than what they would experience during operation. Our software allows us to predict and simulate very accurately what loads will be experienced during operation. Even with this in mind, all our designs are conservative and can tolerate any fluctuating loads and peaks that the plant may experience. These components also have unique design features, such as:
On our larger agitators, gearboxes are designed to incorporate a dry well and heavy-duty output bearings. In the majority of instances, we also allow for an extended bearing distance. Normally, gearboxes are selected on torque alone, but with agitators, the overhung load is large, and the drive is subjected to high external loads. Our selection, therefore, doesn’t only cater for the transmission of power, but also its ability to withstand external forces.
With tanks being larger, the structures the agitator needs to mount onto becomes more susceptible to inaccuracies and misalignment. With the intention of saving costs, many manufacturers allow their gearboxes to be bolted directly onto faulty beam structures. By mounting a machined gearbox directly onto a fabricated structure, it preloads the housing. This causes additional stress within the housing itself. During operation, this misalignment, combined with any twisting of the beams, will cause premature casing failure. AFX-designed gearbox bases have machine mounting surfaces that don’t need shimming and won’t preload the gearbox casing. Bases are designed to withstand much greater loads than what the agitator is subjected to. This enables the base to increase the rigidity of the structure.