Buhler builds feed premix plant in Turkey

by Emily Wilson
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UZWIL, SWIZERLAND — Buhler has constructed a premix facility for the Kartal Kimya company in Turkey, in the industrial district of Gebze, east of Istanbul.

All carrier substances such as calcium carbonate are supplied to the plant by bulk trucks and dumped into intake pits. An effective aspiration system at intake ensures dust-free operation. A check screen separates any agglomerates present, while an inline scale registers the weights before the raw materials are transferred to the dosing bins. Other macro-ingredients are supplied in bags and dumped by hand into the dosing bins. Here, too, an aspiration system works to remove dust.An electronic batching scale blends the carrier and macro-ingredients, and a pneumatic sender vessel system moves the material to the target bins above the batch mixer. This alternative conveying system from Buhler was preferred to a pneumatic conveying system using airlock feeders because its conveying velocity and conveying air volume are substantially lower. The need for cooling and drying the conveying air is eliminated, allowing much smaller dust collection filters and fans to be used. This provides lower energy costs, operating costs and low-wear operation, which is important considering the abrasiveness of the components involved in premix production.

Micro-ingredients are pre-weighed in the laboratory and filled into a manual intake hopper fitted with a check sieve and an aspiration system mixed in a laboratory mixer. Another manual intake system is provided for filling in components from bags. All components are homogenized in the main mixer. The blend is bagged by an electronic gross bagging scale into 25-liter or 50-liter bags immediately after production. The bags are transferred by a special belt conveying system to the logistics hall for shipping.The entire plant is operated from a centralized control room. Kartal tailors the blends to its customer’s specific needs. The constantly changing formulations and the large numbers of components involved require a powerful data transmission system offering visualization of the process. In addition, ISO 9002 demands that it must be possible to retrace all batches. To meet this special requirement, Buhler applied its Viscontrol visualization software.