lion202205 - Tumblr blog

lion202205 · 3 years ago

Text

2022 ultimate: The DIFF Between BHO vs. CO2 Extraction

TWO OF THE MOST POPULAR EXTRACTION METHODS OF CBD OIL

Cannabis extraction has allowed processors to convert almost any quality biomass into a high potency cannabis oil with tremendous aesthetic appeal. Whether it is being used for a vape cartridge or an edible, cannabis oil containing its cannabinoids and terpenes must be extracted from the biomass. Two of the most popular extraction methods of CBD oil include Hydrocarbon (BHO) and carbon dioxide (CO2) extraction. Commonly used in other industries, these methods of extraction have found their way into the cannabis industry.

Butane cannabis extraction requires highly flammable solvents, which has the possibility of fast extraction. Even when these methods are applied correctly, solvents such as butane may remain in the concentrates, leading to a slew of health concerns.

Supercritical CO2 extraction is a cleaner and safer extraction method, it is popular because it produces cleaner concentrates with no residual solvents.

In this post, we will explain CO2 and butane extraction methods. So how do CO2 and butane extract CBD, and what are their drawbacks? Let’s take a look…

Read more: Who is the best? CO2 vs. ethanol extraction of essential oil

WHAT IS A BHO EXTRACTION?

Butane extraction is a form of hydrocarbon extraction. Butane Hash Oil extraction(BHO extraction) is a butane extraction method for CBD oil, which is the process of using a hydrocarbon like butane or propane as the solvent to extract cannabis concentrates, it is a popular method of extracting the valuable compounds from the cannabis.

Butane Hash Oil extraction (BHO extraction) end result is known as butane hash oil (BHO), which is what is used to make up man other forms of consumable cannabis concentrates.

BHO EXTRACTION PROCESS

For the butane extraction method, the user first tightly packs a glass cylinder with marijuana. At one end of the glass tube, a screen ensures plant material does not fall out. This screened end is held over another glass receptacle. Next, a butane torch is held or affixed to the opposite end of the glass tube, and the butane is blown into the tube. The heated cannabis plant material will eventually release its oils and resins, which are collected in the additional container.

PROS

Lower cost of entry for extraction systems

Hydrocarbons’ low boiling point preserves more of the cannabinoids and terpenes for a full-spectrum extract

Wide variety of products available, with differing tastes and effects

Faster runs than CO2 extractions

Can produce a wide variety of extract solutions ranging from distillates to high-terpene full-spectrum extracts (HTFSE).

Often considered a stronger product

CONS

In an unsafe environment or when handled improperly, the highly flammable solvent can increase the risk of fire and explosion

When used improperly, it can increase the risk of residual solvents ending up in the final product.

More difficulty gaining approval from jurisdiction

It may come with higher facility costs

Not as environmentally friendly as CO2 since butane and propane are petroleum products

TWO METHODS TO REMOVE HARMFUL BUTANE

Before consumption, the oils and resins must be cleared (purged) of the butane solvent. To do so, the solution is simply heated. Butane bubbles form in the oil and eventually pop, releasing gas into the atmosphere.

METHOD 1: HOT WATER

Get the large Pyrex dish and put the BHO extract inside of it. Then, put hot water in the outer, larger dish. This will cause the butane to begin to evaporate, which should take between fifteen and twenty minutes. Replace the hot water as needed to keep it hot. For your safety, be sure there is plenty of ventilation during this process.

METHOD 2: ELECTRIC HEATING PAD

Using a purging system is the best way to do it, but many money-conscious people prefer to use an electric heating pad instead. Simply set it to high heat, and then place the medium Pyrex dish on it for an hour or more. Watch it carefully. It is finished once the oil stops bubbling. Honey oil that has begun to become hazy or cloudy in appearance looks that way because of trapped butane. Purge-it again to get rid of all the butane.

HOW CAN I CHECK FOR BUTANE RESIDUES?

One simple way of checking if there is any butane left in it is to touch it with a flame — if it catches, there is still butane that needs to be removed.

IS BHO EXTRACTION GOOD?

BHO extraction method is a good approach for manufacturers but has potential health risks for consumers.

CONS

Often featuring between 60 and 90 percent THC, BHO is one of the strongest cannabis products on the market.

Though BHO often gets a bad rap, this form of extraction creates a delightful end product. BHO tends to be flavorful and features stronger terpene expression than CO2 extraction. Terpenes are flavor and aroma molecules found in plant resins. This means that consumers will get an excellent feel of an individual strain.

In terms of extraction efficiency, BHO extraction is the most efficient and cost-effective method. With an average extraction cycle of less than 1 hour, BHO is the fastest commercial extraction method for CBD oil. So it will be very popular with CBD oil manufacturers, after all, it will bring considerable benefits.

PROS

The BHO extraction end result is considered by many to be a clean, solvent-free product that is safe to eat. However, some will argue that any residual solvent in the concentrate is unacceptable.

An unavoidable fact: BHO extraction will leave butane solvent residues in the extract, requiring technical means to remove them, BHO that is professionally extracted and has passed laboratory tests contains a low risk of residual solvents. Though, homemade extracts are often not pure. So BHO products are generally considered more irritating to the lungs, even with vaporizers.

SAFETY REMINDERS ABOUT BHO EXTRACTION

Even with proper training, equipment, and environment, BHO extraction systems can be dangerous. In 2014 in the US, there were 3 BHO extraction explosions, 30 injuries, and 32 explosion related deaths. This is in comparison to 12 explosions and 18 injuries in 2013.

The National Fire Protection Association has assigned a flammability rating of 4 (on a scale of 0 to 4), classifying n-butane as extremely hazardous. For these reasons, most states that allow for BHO extraction systems require a properly ventilated Class 1/Division 1 explosion-proof room. Both the room and BHO extraction system must be inspected by a certified industrial hygienist or engineer to be sure they conform to regional and municipal codes and nationally recognized accreditations. Workers must be adequately trained and understand the hazards associated with working with closed-loop BHO extraction systems.

WHAT IS BUTANE?

Butane is an organic hydrocarbon with the formula C4H10. It has a boiling point of around 0° C (31° F), making it gas at normal room temperature and pressure. There are two isomers of butane, each with slightly different chemical properties; n-butane has 4 carbon atoms connected in a chain surrounded by 10 hydrogen atoms, and iso-butane has 4 carbon atoms arranged in a “T,” surrounded by 10 hydrogen atoms. Unless otherwise specified, ‘butane’ refers to the n-isomer.

BUTANE AS A SOLVENT

Most BHO extraction operators prefer n-butane due to its lower operating pressure and low vapor pressure.

Butane is relatively non-polar; the molecule has a symmetrical arrangement and none of the bonds are significantly polar, meaning the molecule has almost no charge. As a rule, like dissolves like. In other words, polar solutes will dissolve in polar solvents, and vice-versa.

THC and CBD, along with a large variety of other terpenoids, are relatively non-polar and will readily dissolve in butane, along with lipids and waxes. Chlorophyll, a green pigment found in most plants, can contribute to the foul taste and discoloration of cannabis-derived extracts. Fortunately, chlorophyll is relatively polar and does not readily dissolve in butane.

WHAT IS BUTANE HASH OIL (BHO)?

Butane hash oil — or BHO, as it is more commonly known — is a highly concentrated form of cannabis oil. Once collected, the oil is often smoked directly or vaped.

As the name suggests, butane hash oil is created using the butane extraction method. There are numerous different types of BHO on the market including budder, dabs, wax, and shatter.

Consumers find these extracts appealing due to their relatively high THC content. At the high end, these products may have THC concentrations of nearly 90 percent — four times the typical percentage found in an average bud. Intuitively, this exceptionally high THC content will lead to a faster and stronger high when compared with smoking traditional leaf cannabis. Popular shatters and waxes can be created using either butane or supercritical extraction, and a given producer may prefer one method to another for various reasons, including operational limitations.

CO2 EXTRACTION PROCESS

Supercritical CO2 extraction process is currently the “gold standard” of cannabis extraction methods because it’s cleaner, more efficient and safer than other methods of extraction. Butane extraction, for example, can leave traces of heavy metals. By comparison, supercritical CO2 extraction yields cannabis oils, waxes and rosins with the highest purity level and no residual solvents. In addition, even though CO 2 is a greenhouse gas (a contributor to global warming), when it is removed from the environment, used in an extraction process, and expelled back into the environment, it does not result in any increase in greenhouse gas emissions.

Supercritical CO2 Extraction Process is quickly becoming the preferred solvent in the Cannabis industry. Despite having a more costly initial setup, CO2 is cheaper than butane, making the system more cost-effective to run.

During the CO2 extraction method, the carbon dioxide gas is converted into a liquid and the pressurized solvent is passed through the biomass to dissolve its terpenes and cannabinoids. In its supercritical state, CO2 has the properties of a gas and liquid which make it perfect to dissolve the active ingredients in the plant material.

FEATURES

CO2 is also non-toxic- it is a natural waste product from human bodies and fermentation. Due to this and its gaseous state at atmospheric pressure, all extracts made from SCE are pure and completely clean of any potentially toxic or heavy metal residues that can be left behind in BHO.

The conditions of an SCE system can be manipulated to fractionate desired compounds like terpenes, cannabinoids, waxes, and esters out of the oil mixture in differing concentrations. This also provides the opportunity to refuse undesired compounds like chlorophyll from the extract. Manipulation in this manner makes SCE the perfect option for drug manufacturers looking to obtain higher concentrations of different biologically active components.

CO2 has solvency power at a much lower set of extraction parameters in comparison to other solvents and therefore can extract compounds that usually are degraded at higher temperatures or pressures such as terpenes. Carbon dioxide extracts are accordingly stronger in aroma and flavor and bear a profile that most closely resembles the original plant. These extracts are preferred in the market as their scent and flavoring are highly valued by purveyors.

What is supercritical fluid extraction (SFE)?

Why CO2 is used in supercritical fluid extraction?

PROS

Non-flammable and non-toxic

Relatively affordable and accessible solvent

Eco-friendly

CONS

Relatively longer run time than BHO

Prohibitively expensive systems

Standard operating procedures may result in a lower concentration of terpenes and cannabinoids in the concentrate

May need winterizing with ethanol

THE CO2 EXTRACTION PROCESS FOR CBD OIL

The CO2 cannabinoid extraction process starts with a simple setup. First, the plant material is placed in an extraction column. Next, a compressor and heating element increases the pressure and heat to allow the CO2 to reach its supercritical state. Supercritical CO2 maintains the properties of both a liquid and a gas, passing through the cannabis like a gas while also dissolving materials like a liquid. A sudden reduction in pressure between the material column and the collection jar causes the CBD to separate from the CO2, allowing the raw CBD oil to be collected. Unlike the butane extraction method, this material requires no additional processing to eliminate residual solvents.

The difference between butane and CO2 extraction

CO2 VS BUTANE EXTRACTION

COST

Despite having a more costly initial setup, CO2 is cheaper than butane, making the system more cost-effective to run. In a closed-loop supercritical extraction system, CO2 is constantly recycled- again, reducing cost. As CO2 is produced by natural means, if it is released back to the environment it does not have a negative impact on the atmosphere, making it a much safer and environmentally responsible choice than BHO. SCE does not require the same explosion-proof facility setup that BHO does, or safety equipment and training for operators to work with.

NO TOXIC SOLVENT RESIDUE

Carbon dioxide is gaseous at atmospheric pressure, removing the need for an extra step to remove the solvent from oil extracts as in BHO.

SCE extracts are FDA-approved and safe for use in products ingested by humans.

MORE EXTRACTION OPTIONS

Although both butane and CO2 are chemically inert, BHO is not a fully oxidized product, meaning that the cannabinoids obtained could continue to change the structure and therefore lose the intended effect. The pressure and temperature parameters of both extraction and separation will greatly influence the composition of your final oil product. The solubility and mass transfer properties of the target material within the solvent CO2 determine the operating conditions for that extraction. The conditions of an SCE system can be manipulated to fractionate desired compounds like terpenes, cannabinoids, waxes, and esters out of the oil mixture in differing concentrations. This also provides the opportunity to refuse undesired compounds like chlorophyll from the extract.

Manipulation in this manner makes SCE the perfect option for drug manufacturers looking to obtain higher concentrations of different biologically active components.

UNIQUE CO2 EXTRACT

Uniquely, carbon dioxide has solvency power at a much lower set of extraction parameters in comparison to other solvents and therefore can extract compounds that usually are degraded at higher temperatures or pressures such as terpenes. Carbon dioxide extracts are accordingly stronger in aroma and flavor and bear a profile that most closely resembles the original plant. These extracts are preferred in the market as their scent and flavoring are highly valued by purveyors.

John A. Mackay, Ph. D:Additionally the CO2 is a better extraction for the terpenes in the cardamom. The beta-pinine, Cineole, linalool, alpha-terpinol and bornelole. The increase in the propane pressure will allow us to increase the yield of the CO2 (Illes, V, et. al. Proceedings of the Fifth Meeting of Supercritical Fluids, Nice, France, Tome 2, 555-560).

This example is the same with butane and cannabis. Butane is a stronger solvent and if left too long will continue to pull out more and more polar compounds like chlorophyll. With the fine-tuning of CO2, you can eliminate or you can pull out the chlorophyll if you choose the wrong conditions.

Read More: Busting the Myth: Examining CO2 versus Butane Extraction

So fast extractions are possible with butane but little control of all the material, while CO2 can be tunable and therefore is able to collect all of the same material, just through a segmented process.

In the debate between BHO vs CO2, there’s no question about which method is the winner. BHO may be fast and cheap, but the results are less pleasant for consumers, and can even be dangerous. Clean, tasty CO2 extracts have quickly become more desirable for cannabis consumers. Whether you’re an investor or a consumer, turn your attention to CO2 extraction to get the most for your money.

0 notes

lion202205 · 3 years ago

Text

HOW TO GET THE BEST CO2 CBD OIL EXTRACTION PROCESS?

WHY PRODUCE CBD OILS OR CANNABIS EXTRACTS?

CBD is one of the many compounds found in the cannabis plant. Extracting CBD oil from industrial hemp plants is one of the fastest-growing, most stable, and value-added segments of the broader cannabis industry. Science is just beginning to uncover the medicinal benefits of this cannabinoid, and findings thus far are promising. Over the last few years, cannabidiol has become so popular that it is now being extracted and produced, extraction allows manufacturers to transform hemp or cannabis biomass into bulk ingredient essential oils, waxes, cannabinoids, terpenes, crystals, or distillate oil. These high-quality oils are then transformed into novel food ingredients, supplement active ingredients or additives in cosmetics. CBD oils are typically available in CBD pills, water-soluble formulations, tinctures, and edibles.

CBD oil is especially popular. It is used to treat a host of illnesses and works by interacting with the endocannabinoid system (ECS) without providing users with a ‘high’.

CBD oils make up a major portion of retail sales. In their recent study, The World Health Organization showed that CBD has a great safety track record and has a limited number of adverse events. The report notes that there has been no evidence of any public health-related problems associated with the use of purified CBD. The report did review several therapeutic applications and benefits of CBD oil on the endocannabinoid system. According to the report, hemp oil benefits include aiding in skin conditions to mitigating forms of epilepsy and multiple sclerosis.

WHAT IS THE BEST METHOD FOR EXTRACTING CBD?

There are several ways to extract CBD oils from hemp. The most popular methods use supercritical CO2 or ethanol to dissolve cannabinoids that are in the resinous plant trichomes, leaving the undissolved plant material to be discarded as waste.

Many cannabis experts agree that the CO2 extraction method is the best for producing a high-quality oil that stays potent longer, supercritical CO2 extracts to be cleaner and safer than ethanol derived oils for the following reasons:

PURITY

Ethanol extracts carry with them known and unknown risks related to prolonged and repeated exposure to unnatural denaturant chemicals, that are added to pure ethanol to make the extraction method affordable. Although these chemicals are often removed to “safe” levels, they are not fully removed from extracts. The remaining solvent contaminants are called chemical residuals by the FDA and must be controlled and tested because the residuals have “no therapeutic benefit” and in some cases are toxic or carcinogenic at high levels.

Why is SCF CO2 better than Ethanol Extraction?

TESTING USING INVALID TEST METHODS

A partial list of common denaturants include: acetone, isopropyl alcohol, hexane, hexanes, heptane, butanol, methyl tertiary butyl ether. Testing for “safety” is required but residuals are not always measured in hemp extracts with validated test methods considering the specific denaturant mixture used in extraction. Rather, a generic solvent method is typically employed. This means the risk of missing a major potential contaminant is highly increased.

UNKNOWN RISK OF NEGATIVE HEALTH CONSEQUENCES

Health dangers of such additives are well documented but only partially understood in the context of cross factors including age, health, drug interactions, effects on the brain and cognitive & emotional function, and susceptibility to negative health consequences. Despite all the years of research, more research investigating the long-term solvent exposure in humans is needed to accurately assess risk. Due to these reasons, the healthy, natural CBD you expect from hemp may not be so healthy.

SUMMARY

CO2-derived hemp and CBD oils are widely regarded as the highest quality, chemical residue-free oils produced. CO2 extraction has advantages over ethanol as the extraction media is on many different levels. Drastically lower operating costs are a key benefit of CO2 extraction. Over time, lower operating costs accumulate and continue to build value throughout the life of the equipment.

For the company and consumers alike, CO2 extraction is the best possible method of extracting CBD. It is completely safe and creates very little waste for the company producing it. CBD extracted this way is going to be the purest it can possibly be and contain no harsh chemicals or contaminants. When you’re looking for CBD products for yourself, you should look for companies that extract their CBD in this method. Reputable companies all list their extraction method on their site so you can be sure you’re getting the best possible products.

HOW TO GET THE BEST CO2 CBD OIL EXTRACTION PROCESS?

4 EXTRACTION PARAMETERS OF CBD OIL CO2 EXTRACTION PROCESS

Extraction parameters will determine not only the type, quality, and yield of a cannabis extract, but also the ease and cost of the extraction process.

Supercritical co2 extraction cannabis (weeds) typically choose to start parameters in the 45-60 deg C range and pressures ranging from 3000 to 5000 psi range and then run trials for their particular feedstock and desired final product.

Once the desired extract for the specific feedstock, the experiment is to find the appropriate flow rate to facilitate processing (as quick as possible without icing up, clogging lines, or causing channeling).

Finally, look at solvent-to-feed rates to balance out the completeness of the extraction (yield) versus the extraction time/solvent cost.

PRESSURE

From the initial chosen extraction pressure, increasing pressure increases wax/resin concentration in the extract

Pressure over 5000 psi at 45 deg C causes chlorophyll extraction,

Increasing pressure increases chlorophyll in the extract

Increasing temperature increases chlorophyll in the extract

Higher pressures are harder to maintain if CO2 supply is not continuous (cylinders instead of bulk)

FLOW RATE

Maintaining flow rate at higher pressures is more difficult due to a loss of CO2 supply (especially when using tanks and the cylinders are emptying). Increasing flow rate can cause dry ice accumulation, resulting in a higher chance of icing up lines unless additional heat is applied. Decreasing flow allows for the material to be in contact with the solvent for longer, increasing potential yield. Decreasing flow slows processing.

SOLVENT-TO-FEED RATIO

This is a processing time/solvent cost versus extract quantity amount issue. The correct ratio is the one that is most cost-effective.

CONCLUSION

Ultimately, the selection of extraction parameters is a balancing act: product quality vs quantity, processing time vs yield, and the overall cost to produce the product. The four parameters discussed are the main ones that our customers use to fine-tune their processes.

0 notes

lion202205 · 3 years ago

Text

5 KEY POINTS OF SUPERCRITICAL CO2 EXTRACTION OF ESSENTIAL OIL

WHAT IS SUPERCRITICAL FLUID EXTRACTION?

Using supercritical fluid as a solvent to selectively dissolve solutes in liquid or solid mixtures, supercritical fluid extraction as a new separation technology has developed rapidly in the past 20 years.

0:00

2:14

CBD co2 extraction machine

Supercritical fluid not only has high permeability and low viscosity comparable to gas but also has a density similar to liquid and excellent dissolving ability to substances. Compared with traditional steam distillation and solvent extraction, supercritical fluid extraction is a new separation technology with many advantages.

APPLICATION

Supercritical fluid extraction technology was first industrially applied to decaffeinate natural coffee beans and to extract hop oil from hops. In the past 10 years, great progress has been made in the theoretical basis and application development of supercritical fluid extraction technology.

Supercritical fluid extraction technology has been applied to the extraction of special oils, seasonings, spices, and natural pigments;

Unsaturated fatty acids with high nutritional value and medicinal value can also be extracted from fish oil;

It is used to remove fat from fried food and cholesterol from milk fat and egg powder;

It is used for softening, decolorizing, and deodorizing alcoholic beverages.

SUPERCRITICAL CO2 EXTRACTION OF ESSENTIAL OIL

The whole process of supercritical co2 fluid is carried out in a closed reaction tank, and the time required is very short.

The supercritical CO2 extraction method of essential oils is referred to as SFE. In short, CO2 oil extraction is extracted by pressurized CO2 until it becomes a critical point in a liquid state. The liquid carbon dioxide then acts as a solvent to obtain natural plant matter and volatile oil content and dissolve the carbon dioxide in the liquid. Then, the CO2 is brought back to natural pressurization, the carbon dioxide evaporates back to its gaseous state and what remains is the resulting oily substance.

MATERIAL PRETREATMENT

The main factors affecting the extraction effect in the pretreatment process are the moisture content and particle size of the material.

Different extraction materials require different pretreatment methods. For example, when extracting fresh flavor substances such as ginger, garlic, onion, etc., it only needs to be peeled, cut into pieces, or extracted directly after juice extraction.

CO2 DENSITY

The extraction conditions are generally between 8.0MPa～12.0MPa and 35℃～50℃. It is well known that under higher CO2 density (such as 40℃ and pressure higher than 20.0MPa), SC-CO2 exhibits strong solubility and lower selectivity. In fact, the increase in extraction rate under high-density CO2 is mainly due to the increase of surface wax and other undesired components.Under the condition of CO2 density lower than 0.6g/cm3, it is possible to extract as many essential oil components as possible, and other non-volatile components except surface wax will not be extracted. When the CO2 density is too high, such as higher than 0.85g/cm3, not only does the extraction rate decrease but also the technical difficulty is caused by the increase in the extraction amount of waxes and triglycerides.

The density and dielectric constant of supercritical fluid is large, and the solubility of substances is also large, and it changes rapidly with the change in temperature and pressure.

Therefore, it has strong solubility and selectivity for certain substances, and the solvent and extract are easily separated at room temperature.

The dissolving ability of supercritical fluid is proportional to its density. Near the critical point, if the pressure changes slightly, its density will have a relatively large change. Therefore, for many solid or liquid solutes, if the solute and the solvent are not infinitely miscible, the dissolving ability of the supercritical fluid is obviously related to the pressure. Under different pressures, the range of extracts is different. When extracting low-molecular-weight essential oils (aromatic components) under low pressure, the range of extractable substances expands with the increase of pressure, but the two are not linear. When the pressure increases to To a certain extent, the solubility increases slowly.

EXTRACTION TIME

When determining the CO2 extraction time, the relationship between the equipment energy consumption and the extraction rate should be comprehensively considered. It is not necessary to select the limit time and a single CO2 extraction method but should choose the best time and method that can economically balance the energy consumption of the system way.

Under normal circumstances, when the flow rate is constant, at the beginning of the extraction, because the supercritical CO2 fluid and the solute have not reached a good contact, the extraction amount is small, with the extension of the extraction time, the mass transfer reaches a good state, and the extraction amount per unit time increases until Its maximum value, the corresponding time is the limit time of extraction. After that, the CO2 fluid extraction rate gradually decreased due to the decrease in the content of the components to be separated in the extraction object.

CO-SOLVENT

Cosolvent, also known as entrainer. The addition of a small amount of it can significantly change the phase behavior of the supercritical CO2 fluid system, especially it can increase the solubility of some substances that have little solubility in the supercritical CO2 fluid, and can also reduce the operating pressure of the S supercritical CO2 fluid. Reduce the amount of supercritical CO2 fluid.

Adding 3% ethanol or methanol to egg yolk powder can more than double the solubility of egg yolk lipids at 36MPa and 40℃;

When extracting peanut oil and pepper oil, adding 10% ethanol at 34.5MPa and 60℃ can increase the yield by 230% compared with that without adding it, and adding 10% ethanol at 20.7MPa and 60℃ can increase the yield to 750%.

SEPARATE

The supercritical CO2 extraction and separation of fennel oil adopt two-stage separation. Under different separation conditions, the yields of the two products depend on the pressure of the first separator, but the pressure adjustment of the first separator has a certain range. If it is too high, fats, lipids, and pigments cannot be deposited in the first separator, which will lead to the inclusion of these three types of substances in the second separator, thus losing the advantages of fractionation. Reasonable adjustment of the process parameters of the separator is the key to achieving the purpose of separating different substances.

After the extraction process, the density of the supercritical CO2 fluid must be reduced to selectively separate the extract in the separator.

To implement this separation, there are generally three adjustment methods, constant pressure-temperature increase or constant temperature pressure reduction, or pressure reduction and temperature increase. The specific optimal operating conditions must be obtained through specific experiments.

With different separation pressures, the chemical composition of the extracts will also be different. For extracts that do not perform well with single-stage separation, two-stage or even multi-stage separation should be considered.

0 notes

lion202205 · 3 years ago

Text

Top 4 Questions and Answers about Vibrating Conveyors

WHAT IS A VIBRATION CONVEYOR?

Vibratory conveyors (or shaker conveyors) are used for high-product throughputs and bulk handling applications. They are used primarily in industrious applications where a high level of hygiene is required, e.g., food production, pet food production, and pharmaceuticals. They have an extensive range of uses and can be designed with an open or enclosed tray as well as a full tubular design. They are powered through e-mag coil drives and motors, and they have a variable speed to suit the product and factory requirements.

What is a vibratory crosshead feed conveyor?

A Vibratory Multihead Conveyor is specially designed to feed a measured delivery of the product to the scale. The weigher Vibro conveyors have a variable speed synchronized with the multi-head to deliver the optimum delivery of products on a call on-demand principle. We call this our’ parent & child software’.

Most common is feeding a CCW or Multihead weigher to make sure there is an even spread of produce across the scale head, so the perfect algorithm of 4/5 buckets is selected, making the weighing process even more precise.

Using our powered circular or spigot discharge vibration and synchronization technology, we can exceed most customers’ specifications, and drastically improve your packing line in addition to the best ROI of reducing product giveaways.

What is a vibratory inspection conveyor?

Vibratory Quality Assurance Inspection Conveyors are added to the line for quality control purposes. The vibratory technology will create an even spread of products spanning the conveyor tray’s entire width, allowing the quality control teams to remove bad or unwanted products into the rejection channels. The channels are an integral part of the design to ensure the full equally distributed movement of the product stream.

What is a vibratory cooling conveyor?

As the vibrating conveyor tray is formed from metal, you can then perform multiple applications on the same conveyor. A cooling conveyor cools the product on the tray as it passes from the processing stage to the next through added refrigeration integration. As the product vibrates, it is distributed across the conveyor width to form a monolayer, creating more effective and uniform cooling.

0 notes

lion202205 · 3 years ago

Text

Sheet Metal Bending Process: Basics, Top 7 things, 6 Tips

What is Sheet Metal Bending Process

The sheet metal bending process is a cold bending method to bend/shape the sheets of metal to manufacture a product of certain geometry. It is also a basic operation to make the metal stamping parts.

How can Sheet Bending Process Do?

Force is applied to a workpiece with the help of sheet metal bending machine to transform its geometry to attain a product with the desired shape. The process is not as simple as it appears, yet there are certain dimensions, and rules to be fulfilled to carry out a sheet metal bending procedure, for example, checking the material of the product, calculating the k-factor, and the shape of the metal, and many more. The malleability property of the metal makes it very special in bending operations.

6 types of sheet metal bending

All sheet metal parts have the same goal which is to bend a sheet of metal to attain a certain product shape. But these methods differ in their performing operations. These various types of bending in sheet metal are fulfilled with the help of machines. Different bend sheet metal is different in the bend angle and bends radius with the same goal along with the standard techniques which not only ensure precision in work output but also a better aesthetic workpiece product.

There are six types of bending processes used to form metal that any sheet metal engineer or press brake operator must be familiar with.

V-bending

V-bending is the most common sheet metal bending process. It involves the use of machinery tools called to die and punch. The die used in this bending process is a V-shaped die, while the punch is also designed in a V-angled shape. The punch presses on the sheets of metal into a V-die and this is how the V-bending of sheet metal is obtained.

Roll Bending

Roll bending is a method used to bend sheet metals into rolls or curved shapes. The process employs a hydraulic press, a press brake, and three sets of rollers to make different bends or a big round bend. It is useful in forming cones, tubes, and hollow shapes as it takes advantage of the distance between its rollers to make bends and curves.

U-bending

In terms of principle, U-bending is akin to V-bending. It uses the same instrument (except a U-die) and process, although the only difference is that the shape formed is U-shaped. U-bending is very popular. However, other methods produce the shape flexibly.

Rotary bending

The rotary bending method is deployed wherever a bending of greater than a 90-degree angle is required. It can also be considered similar to that of V-bending, but the output in this process is more uniform and aesthetic as the metal sheet bending machine used in this method doesn’t scratch the surface of the sheet.

Edge bending

This technique of edge bending sheet metal helps the manufacturer to bend the edges without damaging them. The sheet metal edge bending method is most commonly utilized in those sections of sheet metals that are shorter than the remaining metal part. It helps eliminate the sharpness of the corners and increases the aesthetic appearance of the outcome.

Wipe bending

Wipe bending is another method used in bending sheets of metal edges. The process depends on the wipe die. For example, the sheet metal must be properly pushed onto the wipe die. The wipe is also responsible for the determination of the sheet metal’s bend inner radius.

What Materials Are Good For Sheet Metal Bending Processes?

These are some of the best materials used in various types of bending in sheet metal. Carbon steel is the most commonly used material among the above-mentioned materials.

Carbon steel

Carbon steel is one of the most flexible and strong materials to be used in a sheet metal operation. As this material is recyclable, hence it will help to reduce the carbon footprints as well.

Aluminum

Aluminum is largely used in lightweight applications. Special care must be taken in bending the aluminum material to avoid collapsing or cracking in the corners of the material.

Stainless steel

Stainless steel comes to one’s mind first when the resulting product needs to have the properties of robustness and better metal strength. Stainless steel also requires the use of a high-power sheet metal bending machine to shape the product.

Titanium

Titanium is corrosion-resistant material and high strength material – much suitable for sheet metal bending techniques. If your product is medical or sports equipment, then the most preferred material from your list should be titanium.

Copper

Cost is the strongest anti-corrosive material yet the cheapest. High precision sheet metal bending is obtained from copper. Copper is a tested material being used widely by many metal bending industries throughout various applications.

3 tips For Bending Sheet Metal

While manufacturing a metal product, the sheet metal bending rules must be kept in mind and be proficient in multiple processes to avoid failure. It can become difficult if the proper measures are not taken.

To ensure that your metal bending goes perfectly, these are some tips to be considered in bending sheet metal. Making sure to check each of the 3 tips will help you achieve a product with greater efficiency.

Make use of bend allowance

Bend allowance is a property of the metal to the extent it can be bent. We recommend you make bend allowance calculations that determine the length of the sheet required to make a bend of a specific angle and radius. Keeping the bend allowance and bending force into consideration during a manufacturing process will help you to obtain a neater product outcome. It will also help you achieve an accurately flattened manufacturing model.

Use Heat for thick/heavy Bends

Some metals are likely to break or crack when bending is made from the force. Such metals require the use of heat instead of force to make the desired bend in sheet metal. Hot forming and Annealing are two technical terms when it comes to bending with heat. Annealing helps to soften a metal – more malleability. While hot bending is simply the use of heat till the metal gets red and then using force to bend it. These tricks majorly reduce the risk of metal braking and cracking.

Don’t bend to a Sharp Internal Corner

Sharp internal corner bending means greater internal stress. Even if the metal is ductile and malleable, it may end up cracking. This issue can be majorly avoided if you consider the radius of the bending tool. You should slowly work back and forth between your bend lines until the sheet metal is bent to the desired angle. An eye should be kept on the inside bending radius, which must be equal to the forming sheet metal thickness. An example can be the way, if you are bending a sheet thickness that is 3 mm thick, then the inside bend radius should also be 3 mm. The same is the case with bending angle, which means that it must not be greater than the overall thickness of the metal sheet.

7 Things to Consider About Sheet Metal Bending in the Design Process

Bending is one of the most popular metal fabrication processes. This involves the manipulation of flat sheets of steel, aluminum, brass, and other metals by pressing and bending to obtain new usable shapes.

Engineers can turn sheet metals into highly functional pieces through the bending process. Bending is a crucial design process in metal fabrication. A metal sheet is made to take shape of the final product and that’s why this is a vital process. Below are the things to consider about sheet metal bending;

Bending Direction

When bending sheet metal, you should ensure that it’s perpendicular to the metal fiber direction. Bending sheet metal parallel to the fiber metal direction results in cracks at the bend. Also, the bending strength reduces and the sheet metal may break easily.

Minimum Flange Width

In your drawings, the flange width should not go under four times the thickness of the metal. This is to avoid the occurrence of marks during the metal fabrication process.

Bending Clearance

When bending sheet metal, a particular gap should be secured to avoid bending failure that is often caused by interference. When there is no gap between two bend edges, interference ought to happen. A clearance of at least 0.2mm can effectively avoid this bending interference.

Bending Height

Sheet metal bending height must be at least two times the metal thickness plus radius. When the bending height is too low, sheet metal might be deformed and twisted. This makes it challenging to obtain ideal dimensional accuracy and the preferred shape.

Also, bending beveled edges leads to bend distortion. This occurs when the bending height is too small.

Minimum Sheet Metal Bending Radius

The minimum radius of bend sheet metal depends on the tools used and the bending process. More ductile metal sheet tends to have a smaller inner bed radius. To maintain maximum strength, the bending radius should exceed the minimum bending radius of the sheet metal. Each metal has its standard minimum bending radius.

A big metal radius might not translate to better results. Having a too large bend radius might translate to a larger bending spring back. Also, it might prove challenging to achieve a perfect bending height and angle. It’s ideal if the bend radius is reasonable.

While most metal fabricators emphasize on a zero bending radius, it’s not always the best idea. Zero radius causes external breaking or cracking or metal. Also, it reduces bending strength, especially in hard sheet metal materials.

Minimum Hole Size for Sheet Metal

The thumb rule for sheet metal design is that the hole’s diameter should be equal or larger than the thickness of the metal. When drawing holes, it’s vital to remember that too small holes that might break the tool. Small-size punches are used for small sheet metal holes. The lesser the size of the punch, the higher the chances of breaking.

Choice of Material

Different materials can withstand specific bending processes. Generally, metal sheets of a regular thickness of 1.3 mm can withstand almost anything. They are easy to bend and maintain their maximum strength. However, not all materials behave the same. Thicker steel sheet metal might behave utterly differently from a similar-sized aluminum sheet metal. Your results depend on the metal fabrication experts you choose for the task.

0 notes

lion202205 · 3 years ago

Text

What is the difference between cold bending vs hot bending?

Cold bending and hot bending

While there is metal profile bending multiple methods available, most fall into one of two categories:

Cold bending

Hot bending

Cold bending methods often rely on sheer physical force to help bring the metal profile(e.g. pipe beams) to its final shape while hot bending methods use careful heating to reduce the force required.

There are pros and cons to both the hot and cold bending processes, depending on the type of material you need to be bent and the angle of the bend required will determine the degree of bending possible and the final shape of the metal profile.

Cold bending

Cold bending is done by machines without inducing any heat into the material to be bent. These machines will generally wrap a pipe or sheet of material around a shape with a force that causes the pipe to bend.

This process is quick and the materials don’t need to cool down afterward; however, cold bending can have disadvantages if materials are fragile. Radical bends are also not possible with cold bending. In most cases, the machine will need to be filled with sand to achieve any bend that could be considered extreme.

Cold bending machinery is usually lower in cost than hot bending machinery, as it is less complex. This can make it an attractive option for smaller companies.

4 methods of the cold bending process

Rotary Draw Bending: A pipe or tube is bent using a combination of dies and other various components working in a rotary action. This action draws the pipe or tube forward making the desired bend. Rotary draw bending can also utilize mandrels.

Mandrel Bending: A mandrel is placed inside the tube or pipe that is being bent, especially with thinner wall materials, to prevent defects that can occur in the piece’s bend such as rippling, flattening, or collapse.

Compression Bending: Bending a pipe or tube using a stationary die while a counter die bends the material around the stationary die.

Roll Bending: Used when large radius bends or curves are required, this method passes a piece of pipe or tube through a series of three rollers in a pyramid configuration to achieve the desired curve.

Benefits of Cold Bending

Cold bending does not require the use of fuel to heat the steel before processing, and the additional time and effort of heating and then cooling the steel are eliminated. Cold rolling results in a smoother, more finished surface and generally causes less deformation of the item being processed. One additional benefit is the increased strength imparted by working the steel while cold. When steel is manufactured at high heat and then allowed to cool it develops an internal crystalline arrangement. Working steel at ambient temperatures below the point of crystallization has been shown to enhance strength at a molecular level by compressing and distorting the crystalline structure. As the molecules become compacted they are unable to move as easily and, therefore, the steel becomes stronger.

Cold Bending for Different Steel Configurations

Any cross-section and size of steel can be cold bent or rolled as long as it can fit into existing dies and rollers. Cold bending is most commonly applied to pipes of less than 10 inches in diameter, channels, I-beams, angles, and rectangular, round, and half-round bars. Large scale steel products such as plates can also be worked but sizes are limited due to the force necessary and the size of the rolling equipment needed. The bending process can be used to create gentle, large-diameter curves, 90ｰ corners or long series of pipe coils in which the pipe bends in a succession of 360ｰ circular turns.

Why Cold Bending is Necessary

Cold bending, particularly when it is done using a roll bender, can be used when there is no way to heat metal before it can be bent. It is also utilized when it is necessary to have a large, smooth bend in a pipe or with sheet metal. Pipes, in particular, need to behave gentler curves in order to accommodate water or other fluids that may pass through them, and cold bending is sometimes the only way to create these curves and large bends.

Cold bending is also cheaper in many cases; the equipment and materials needed to work with heated metal are expensive. By working with cold metal whenever possible, pipe fabricators and metal workers can save on production costs. Finally, some metalworkers find that cold bending creates more aesthetically pleasing final products, with smoother finishes and gentler curves that often aren’t possible through other methods.

Hot bending

Hot bending is another name for induction bending. These machines are highly effective at bending pipes because they are fast, precise, and make few errors.

Induction (Hot) Bending is a precisely controlled and efficient metal profile bending technique. Local heating using high frequency induced electrical power is applied during the induction bending process. Pipes, tubes, and even structural shapes (channels, W & H sections) can be bent efficiently in an induction bending machine. Induction bending is also known as hot bending, incremental bending, or high-frequency bending. A couple of downsides are that the materials need to cool down after hot bending and the machine is often more expensive than a cold bending machine.

Hot bending for pipe

For bigger pipe diameters, when cold bending methods are limited, Induction bending of pipe is the most preferable option. Around the pipe to be bent, an induction coil is placed that heats the pipe circumference in the range of 850 – 1100 degrees Celsius. By heating a certain point on a pipe, induction bending enables the pipe to be bent without very much effort. No filler is required in the machine, which prevents a good deal of distortion. The heating process is the most time-consuming element of the process; however, after this, bending is quickly achieved.

It requires much less physical force than cold bending methods and can produce bends of similar or higher quality with no filler materials, mandrils, or other additions used to avoid distortion.

While it minimizes diameter reduction at the bend site, induction bending causes some changes in pipe thickness.

Typically, the intrados — or inner section of the bend — will become thicker while the extrados — or outer section of the bend will become thinner.

The method is most often used in large diameter piping and tubing and long radius bends.

However, it also has uses in smaller piping diameters and short radius bends.

Induction bends are normally produced at standard bend angles (e.g. 45°, 90°, etc.). However, depending on the requirement they can be custom-made to specific bend angles. Compound out-of-plane bends in a single joint of pipe can also be produced. The bend radius for induction bending is specified as a function of the nominal pipe diameter (D) like 5D, 30D, 60D bends, etc.

Hot Bending vs Cold Bending

Working steel at high heat above the point of crystallization means that crystallization will occur after the steel has been worked and therefore the steel will not be any stronger than unworked steel. Heating steel that has already been cold-bent or rolled will cause the material to lose the extra strengthening gained from the process by allowing the steel to regain its internal crystalline structure. The trade-off between cold and hot working processes is that in exchange for the added strength of cold working the steel can become more brittle, while heat worked steel generally retains greater ductility.

0 notes

lion202205 · 3 years ago

Text

what is pre-bending in plate rolling?

What is pre-bending?

Plate rolls need a place to grab the material during forming. That’s why, in any plate rolling situation, you have a narrow unbent flat section on the plate’s leading and trailing edges. An operation known as pre-bending reduces the length of these unbent flat sections.

You perform a prebend to the plate’s leading edge, then the trailing edge, and then perform the actual rolling. In production bending with double-pinch, four-roll systems, it’s possible to prebend the leading plate edge, perform the rolling, and then the prebend (in this case it could be called the post bend) to the trailing edge. But in most common setups, pre-bending is performed before rolling the cylinder.

WHY NEED PRE-BENDING？

Pre-bending is to reduce the flat part in the bending process.

WHAT IS THE FLAT PART OF A COLD ROLLING BENDING?

After bending due to the position of the rollers on the workpiece inevitably remains a flat part at the ends of the metal profile. This flat part is approximately half the length of the gap between the centers of the lower rollers.

HOW TO REDUCE IT?

Although the appearance of a straight part is considered to be a flaw of asymmetrical roller with 3 rollers, their simple structure, comfortable use, and low price still make them the most wanted model of roll metal section bending machines.

In addition, there are methods which we can use in order to easily eliminate this problem. You can find some of them below:

PRE-BENDING

This solution involves bending the edges of the workpiece on a press brake before the roll bending process.

ADDING A “BASE” FOR THE WORKPIECE DURING THE PRE-BENDING

This method involves the installation of a “base” together with a workpiece designed for bending and performing the edge pre-bending process on the circular bending machine itself. The application of this method should take into account the possibilities of the circular bending machine and calculate the strength of the applied force on the “base” and the workpiece.

Leaving allowance at the ends – if you add an appropriate allowance at plate ends before the bending, you can, after the bending, cut off those parts into a desired bending shape.

ASYMMETRICAL MODEL

Thus, in a model with an asymmetric position of the rollers, the lower rotating roller can be lifted up to the middle of the gap between the two rollers, while the other can be positioned in the appropriate position so that the starting part of the metal profile can be folded to form a circle. The flat edge can be eliminated on both sides by turning the rollers in half of the bending process by folding the back of the profile. Additionally, the workpiece can also be turned around after completion of one bending cycle and then the back part will become the front and both flat edges will be eliminated.

3 ROLL BENDING MACHINES

The plate roller machine with 3 rollers usually has two fixed rollers, while the upper vertical roller is positioned accordingly in order to complete the desired bending. By changing the relative position and rotating movement of the working roller, continuous plastic deformation is achieved in order for the workpiece to receive a predetermined shape.

While bending, the workpiece is positioned between the lower and upper rollers. After placing the sheet between the rollers, the upper roller is lowered to secure the workpiece, and at the same time, it has achieved sufficient pressure on the sheet, generating plastic bending. When rotating the roller there is friction between the sheet metal and the roller, so the sheet moves in its longitudinal direction. At the same time, the upper roller adds pressure to the workpiece.

When the roller crosses the lower limit of the upper roller (the roller deformation zone) in one turn and the pressure exceeds the bending limit, plastic deformation occurs and the sheet is folded to its desired dimensions by its entire length. By adjusting the relative position between the lower and upper rolls, the sheet can be folded to a diameter that is not less than the diameter of the upper roller. Here you can see the principle of the symmetrical circular bending machine with 3 rollers:

Rollers 2 and 3 move in the same direction and at the same speed. Because of the friction between the sheet metal and the rollers, the workpiece moves in advance. By adjusting the position of the upper roller, the desired bending angle can be achieved. If the workpiece does not achieve the proper curvature after the first bending, it can be adjusted and started the process in the opposite direction until the desired shape is achieved.

Pre-bending

After bending due to the position of the rollers on the workpiece inevitably remains a flat part at the ends of the sheet. This flat part is approximately half the length of the gap between the centers of the lower rollers. Although the appearance of a straight part is considered to be a flaw of asymmetrical roller with 3 rollers, their simple structure, comfortable use, and low price still make them the most wanted model of roll sheet metal bending machines.

– this solution involves bending the edges of the workpiece on a press brake before the roll bending process.

Adding a “base” for the workpiece during the pre-bending

– this method involves the installation of a “base” together with a workpiece designed for bending and performing the edge pre-bending process on the circular bending machine itself. The application of this method should take into account the possibilities of the circular bending machine and calculate the strength of the applied force on the “base” and the workpiece.

Leaving allowance at the ends

– if you add appropriate allowance plate ends before the bending, you can, after the bending, cut off those parts into a desired bending shape.

Regarding the asymmetrical models of roll bending machines with 3 rollers, the position of the rollers is better adapted to eliminate the flat edges of the sheet, in which case the lower rollers can also be mounted vertically. Thus, in a model with an asymmetric position of the rollers, the lower rotating roller can be lifted up to the middle of the gap between the two rollers, while the other can be positioned in the appropriate position so that the starting part of the sheet can be folded to form a circle. The flat edge can be eliminated on both sides by turning the rollers in half of the bending process by folding the back of the sheet. Additionally, the workpiece can also be turned around after completion of one bending cycle and then the back part will become the front and both flat edges will be eliminated.

4 roll bending machines

In addition to machine tools for roll bending with 3 rollers, there are on the market machines for roll bending with 4 rollers. They offer quicker and easier management, but they also have a higher price.

The principle of operation of the rolling machine with 4 rolls is similar to the machine with 3 rollers, with the main difference being that the additional roller is used for better input of the material and execution of the process of pre-bending. During bending, the upper and lower rollers are static, the material is firmly positioned between them, and the side rollers move and bend the material. In order to eliminate the flat edges of the material, the lower roller moves upward to hold the material firmly, and the side roller moves and occupies the position for pre-bending. Unlike a roll bending machine with 3 rollers, where during the pre-bending it is assumed that the material is lowered when entering the machine, in the rolling machine with 4 rollers, the material is positioned horizontally, allowing the use of motorized horizontal material holders when inserting materials in certain models. In addition, the input of materials can be carried out on both sides, so the machine can be placed next to the wall and save space.

Advantage

The advantage of a rolling machine with 4 rollers has a unique complete bending process. The machine accepts the material in one stroke, performs the pre-bending, and continues to bend the sheet. This system does not require an operator to remove, turn and then straighten the material after pre-bending, as is the case with 3-rollers bending machines. The material remaining in the machine makes the machine with 4 rollers up to 50% more efficient compared to 3-roller models and allows the material to bend at the desired diameter immediately after pre-bending. The bending of the flat edge starts after bending the material in one direction.

The side rollers are positioned to the left and to the right of the bottom roller and have their own axes. The independent axis of each roller allows perfect bending. The “rear” side roller (located on the other side of the material insertion) also has a rear end stop function and aligns the material. This feature allows the operator to work without the assistance of other people. Bending in the shape of the coupe is also possible on the machine with 4 rollers. The side rollers can be positioned in the corner for making the coupling and the bottom roller can be lifted to hold and position the material.

0 notes

lion202205 · 3 years ago

Video

youtube

What machine do you use to bend aluminum? Strech forming machine can do it!

0 notes

lion202205 · 3 years ago

Text

Best High-Quality Plate Bending Machines - 2022 Buyer Guide

WHAT IS PLATE BENDING MACHINE?

A Plate Bending Machine (also named Plate Roller, Plate Rolling Machine) is a device for the radial forming of flat sheets. The Plate Rolling Machine works similarly to a Profile Bending Machine. However, its design is much simpler.

The Plate Bending Machines are available in a wide range. The smallest devices are table machines with manual operation by a hand crank. The largest Plate Rollers are found in shipyards and can bend sheets several centimeters thick, for example for ship armor.

HOW DOES A PLATE BENDING MACHINE WORK?

The sheet metal is pushed between the rollers of the plate rolling machine. If it is moved during the bending process, particularly large radii can be produced.

This is very advantageous for tanks or silos, for example. With the moving bending process, the working range of small plate rollers can be enlarged. The advantage of the bending process is that the sheet cannot buckle during forming. Unwanted hardening or disturbances in the outer geometry are thus prevented. Since a plate bending machine only processes sheet metal but can produce a wide range of bending radii, it is technically very simple.

WHAT IS PRE-BENDING IN PLATE ROLLING?

If the plate ends can be bent prior to rolling, then no extra material is required. This process is called “pre-bending.” Pre-bending can be in a three-roll or four-roll plate roller.

The capacity of a plate bending machine is defined by the maximum thickness and the minimum radius combinations that can be pre-bent for a given plate of maximum width. Pre-bending saves time. You do not have to cut then roll, cut then roll, etc. Pre-bending also eliminates flat spots and material waste.

3 ROLL VS 4 ROLL PLATE ROLL

3-roll bending machines are similar to 4-roll bending machines. The main difference is that a 4 roll machine will have a smaller flat spot on the leading and trailing edges.

The biggest benefit a 4-roll plate bending machine has over a 3-roll plate bending machine is it makes bending processes easier and simpler. The 4 Roll Plate Rollers are fully capable of performing the same functions as a 3-roll bending machine. Some models also can perform similar functions as a press brake. Furthermore, 4-roll bending machines make it possible to create rectangular and square-shaped output by carefully bending the metal in specific areas as it passes through the machine.

3 IMPORTANT PARAMETERS OF THE BENDING MACHINE

BENDING CAPACITY

Bending Capacity on a plate roll is the capacity at full width the machine is capable of. Rated in mild steel, a ¼” X 10’ plate roll is capable of bending ¼” thick mild steel in a 10’ width to 1.5X the top roll diameter in a single pass but be careful as it may not be able to pre-bend that same material.

PRE-BENDING CAPACITY

Pre-Bend is the initial bend a plate roll operator must make before actually rolling the material. The process involves pinching the material firmly between two of the rolls and then using the side or lateral roll to force the material into an initial bend before rolling commences. This process must be repeated on each end of the plate being rolled to avoid large flattened sections at the mating ends of the cylinder. Pre-Bend capacity is always less than that of the rated bending capacity so it is important to ensure the rolling system you are looking at can properly pre-bend the material you are working with.

YIELD STRENGTH

The yield strength is the strength of the material you are rolling, or better put, the strength of resistance to bending that the material has. The harder the material the higher the yield strength and the larger/stronger the plate roll must be to roll the material. Yield points vary greatly from Aluminum to Stainless and other materials in between. Make sure you know the Yield strength of your material as plate rolls are all offered on mild steel (30,000 PSI) yield strength rating but can be sized in accordance with your needs.

HOW TO IDENTIFY THE RIGHT PLATE ROLLING MACHINE?

Choosing the right type of plate roller is the first step. As there are various types available and at various prices. When it comes to choosing a plate roller, alongside choosing the correct type it’s imperative that you get the correct size. If the size of the plate bending machine doesn’t match your application you’re going to waste your money unnecessarily. Getting the right type and size for the job should be a priority. To determine what size of plate roll you’re going to need or benefit from the most you’ll need to consider the types of applications, the material you will be rolling mostly, and the operator skill level you have to work with.

Choose the type of plate rolling machine that will perform your work the fastest with the least amount of intervention involved. As 2-Roll bending machines are dedicated to one specific type of application they are not well suited for the job shop. In most job shops and plate production facilities, we see a large variety of initial pinch, pyramid style 3-Roll Bending machines, and 4-Roll Bending Machines. For simple round sections, an initial pinch or 3 Roll Double Pinch Design can be selected, however, for more complex geometry a Variable Translating Geometry or 4-Roll machine with CNC Controls should be used.

5 KEY POINTS WHEN PURCHASING A PLATE BENDING MACHINE

We covered the general guidelines and uses for the various types of plate bending machines, but when you purchase a new plate rolling machine you will need to have some important information about the plate bending machine, which will help guide you in finding a machine to fit your bending application needs:

What you need to know:

THE TYPE OF MATERIAL

The first thing you need to do before you start searching for the best plate roll bender is to determine the type of materials you will be using in your project. Here, you’ll have to consider things such as thickness, width, diameter, strength, and yield. These elements determine the amount of pressure you’ll need and the max and min diameter and width of the plate roller you’ll use.

THE MINIMUM DIAMETER OF THE BENDING

Taking the thickest material you will be working on and the minimum diameter you will be rolling that material down to will help determine the plate roll size. Plate rolls generally use the 1.5 rule, meaning that a diameter rolled can be no less than 1.5X the top roll diameter. Knowing the minimum diameter you need along with the yield strength of the material is critical in selecting the right plate roll.

HOW LARGE DIAMETER ARE YOU PRODUCING?

The larger the diameter rolled the more the need for additional supports around the plate roll. Most manufacturers offer side supports as an option to support the sheet being fed into the rolling process. However, your application may also call for overhead support if a large radius is required and the rolled sheet is being sent high into the air. The combination of side and overhead supports can assist in supporting the sheet during the process and avoid any back bending caused by the unsupported weight of the material itself.

THE WIDTH OF THE MATERIAL

The machine rolling width capacity is very important. The Plate Rolling Machines are available in a range of widths but consider a plate roller with a width capacity that would suit 80% of your production. The wider you go in capacity the larger the top will be. Therefore, increasing the minimum bending diameter.

The overall rolling capacity is determined by the physical length of the rolls. When purchasing a plate roll make sure you are sizing the roll length for the maximum width of the material you will be rolling, understanding that the longer the rolls the larger the roll diameter has to be in order to maintain strength under rolling pressure. The adverse reflection of that is the larger the diameter you will need to be rolling.

WHAT IS THE THICKNESS OF THE MATERIAL YOU WANT TO BEND?

It is important to consider but also remain realistic on the maximum thickness of the plate required. If you are unrealistic in your selection of sheet thickness you may end up with a plate bending machine that is too large for your core production as this would also affect you’re your minimum bending diameter capacity and rolling quality on thinner material.

WHAT IS THE PRODUCTION QUANTITY YOU REQUIRE?

For you to get the best plate roller machine, you need to know the quantity of your output. This will help you determine the type of plate roll machine that will resonate with these needs. If medium to large production required an electric or hydraulic sheet bending rolls with a digital display for roll positions could help speed up your production. The CNC three and NC or CNC four roll bending machines are considered to be the best for massive projects, but they boast distinct operational complexity, accuracy levels, and features. You’ll have to choose whether you’ll prefer the three-roll bending machines that are known for their versatility and affordability, or the four-roll bending machines, which are swift, accurate, and precise.These are the critical factors that have to be taken into consideration when you select a plate bending machine. If you have a plate bending job that requires a new plate roller then contact a BIT representative to help you find the bender that will meet your specifications, production demands, and budget.

Looking for a new plate bending machine? Have the 5 specifications listed above handy and give us an e-mail at [email protected] to find your best plate roller option.

0 notes

lion202205 · 3 years ago

Text

The top 6 FAQ let you know the air slide fabric

WHAT IS AIR SLIDE FABRIC?

HOW IS AIR SLIDE FABRIC WORKING?

Air slide fabrics are meant for pneumatic conveying of powdery and granular products like cement as well as alumina. However, air slide fabric is also useful for other materials as well. This solid fabric is designed for air sliding purposes.

WHAT IS THE MATERIAL MADE FOR AIR SLIDE FABRIC?

Air slide fabrics are available in different materials with different grades of air permeability as well as thickness based on the purpose. Air slide fabrics are also known as complete set aero cloth, air slide canvas, air slide belt fabric, woven air slide material, pneumatic conveyor belt, and air-permeable fabrics.

Double Dragon Fabric(DDF) provides good quality polyester air slide fabrics for air slide systems, which can be divided into polyester spun yarn air slide fabric, polyester filament air slide belts, and polyester nonwoven air slide cloth for different usages and requirements from the clients.

FILAMENT POLYESTER AIR SLIDE FABRIC

The filament polyester air slide fabric with a smooth surface and equal air permeability, strong construction, excellent for abrasion resistance, with the longest service life for the polyester material air slide fabrics.

SPUN YARN AIR SLIDE FABRIC

WHAT ARE THE ADVANTAGES OF AIR SLIDE FABRIC?

With controlled permeability, air slide fabric can help enhance the conveyor’s efficacy. It also ensures that the powers will be mixed evenly.

While transferring the powder, air slide fabric along with the pressed air of the flume makes dry powder to be transformed into fluid particles so that the equipment isn’t damaged and disturbed from abrasion. And thus it reduces repair works to a good extent.

Moreover, while being transferred to an airtight flume, the particles won’t be lost. And this certainly saves overall cost without polluting the earth.

WHICH FEATURES FOR AIR SLIDE FABRIC?

Air slide fabrics are smooth, clear, and come without any deformation, ensuring dimensional stability.

Resistant to wear and tear high temperature, and corrosion and thus ensures longer life

Air slide fabric doesn’t absorb moisture, doesn’t form caking

Air slide fabric is resistant to abrasion, resistant to decomposition, and rotting, It hardly shrinks even in a hot and humid climate

It ensures stable fluidization, needs little maintenance, and consumes less energy

WHAT KIND OF APPLICATION OF AIR SLIDE FABRIC?

Air slide fabrics come in handy for different industries.

Power Stations – It is often used in power stations for transporting discharging flue ash, filtered dust, and coal dust.

Chemical Industry – It is used for conveying sinter dust, Thomas meal, catalysts sodium sulfate, soap powder, rubber components, and soap powder as stated by reputable air slide fabric manufacturers.

Construction Industry – Airlift slide is used for transferring gypsum, cement, limestone, calcium hydroxide, furnace dust, lead monoxide, acid crystals, pure clay, phosphates, magnesite concentrate, ground fluoride, and quartz.

Tanks and Silos – Air slide fabric is used for mixing equipment, discharging systems, warehouse units, and homogenizing systems.

0 notes

lion202205 · 3 years ago

Text

ROLL FORMING MACHINE VS PRESS BRAKE, WHO IS BEST? HOW TO CHOOSE?

WHAT IS ROLL FORMING AND THE ROLL FORMING PROCESS?

ROLL FORMING

Roll forming is a flexible, responsive, and cost-effective alternative to extrusion, press braking, and stamping.

ROLL FORMING PROCESS

Roll forming is an efficient, effective shaping that delivers tight tolerances on complex profiles. Roll forming is a reliable, proven approach to metal shaping that is ideal for modern applications. This process uses a continuous bending operation where long metal strips, typically coiled steel, are passed through consecutive sets of rolls at room temperature. Each set of rolls performs incremental parts of the bend to produce the desired cross-section profile. Unlike other metal shaping methods, the roll forming process is inherently flexible. Secondary processes can also be integrated into a single production line. Roll forming increases efficiency while reducing operational and capital costs by eliminating unnecessary handling and equipment.

WHAT ARE THE ADVANTAGES AND BENEFITS OF ROLL FORMING COMPARED TO OTHER METAL FORMING PROCESSES?

High-volume capacity

Ultra-precise processing to very tight tolerances with excellent part uniformity and superior surface finishes

More flexible and responsive than press braking or extrusion

Accommodates metals with variable surface coatings, flexibilities, and dimensions

Processes higher-strength steels without breaking or tearing

Creates stronger and lighter structural components using less steel

METAL FORMING STEEL AND METAL MATERIALS

Cold-rolled steel

Hot-rolled, pickled, and oiled

Pre-painted steel

Galvanized steel

Aluminum

Titanium alloys

Inconel®

Hastelloy®

Stainless steel

High-Strength Low Alloy (HSLA)

Brass

Bronze

Copper

Martensitic grades

Dual phase

Ultra High Strength Steel

TRIP Steel

ROLL FORMING VS BENDING PROCESS

Roll forming is the continued process for steel strips to make the required section profile in any length as we all know bending has a limited length and will be done through several steps not continuously.

Roll forming machine can make a close type section with roller efforts under proper design, but the bending machine cannot make any close pattern section.

The only advantage of the bending machine vas the last generation of roll forming Line is can produce a profile with different section drawing among lengths. For example, the 9-meter octagonal light beam can be produced by a bending machine cause the strip width and section drawing are not the same from bottom to top.

The advantage of a new generation of roll forming vs the old type is we can form different drawing sections with one roll forming line by automatic roller change the old roll forming machine just produce one specific section of the profile. So bending different sizes of sections by the same strips is not advantageous anymore compare with new roll forming machines.

For production time and energy usage with labor cost, for sure roll forming line are more economic and fast. One line of automatic roll forming can easily operate by 2 workers at normal speed (15m/min).

ROLL FORMING VS PRESS BRAKING

We want to explain Roll Forming and Press Brake, Then provide a comparison between roll forming and Press Brake bending processes. Roll Forming and Press Brake are Two processes with the same result. in sheet metal fabrication while you can see the bend it’s often not clear which method was used. However, roll forming and press braking are very different ways of getting the same result, and their economics are completely different too.

PRESS BRAKE BENDING PROCESS

A press brake is a machine pressing tool for bending sheet and plate material, most commonly sheet metal. It forms predetermined bends by clamping the workpiece between a matching punch and die.

Press braking, or brake forming, is a metal deformation process that aligns a piece of sheet or plate metal along an axis. This is achieved by using a machine pressing tool (press brake) to clamp the metal piece between a punch and a die set for prearranged bending.

Press braking ensures a highly precise metal bend for several types of parts. The press braking process makes a variety of shapes, some of the most common shapes being a 90° rib form, V bottom, channel, closing, double form, hat channel, offset, open hat channel, and others.

FEATURES OF PRESS BRAKE BENDING

Press braking is efficient and cost-effective

small volumes and with shorter part lengths

Larger orders get expensive very quickly

unable to handle longer parts

brake press is normally easier to set up

Brake press tooling is normally less expensive than roll forming or stamping

difficult to provide value-added features like holes or punched shapes during the process

the force of the die shaping the metal often leaves scrapes on sheet metal

SOME PRESS BRAKE TYPES

Mechanical press brake: Designed to convert circular motion into linear motion.

Pneumatic press brake: Uses air pressure to move the ram.

Hydraulic press brake: Uses hydraulic oil and a hydraulic pump as a power source.

Servo-electric press brake: Uses a servo-motor that forces the ram to move vertically.

ROLL FORMING PROCESS

In roll forming the metal shape by stretching it through pairs of rollers that one of them supports the underside and the other on the top surface. Each pair is shaped to provide a little more deformation. Therefore, geometry is increased a little more until the last pair produces the final shape required. by Using more complex roller shapes, it’s possible to put in multiple bends.

Roll forming is a type of metal bending that involves the continuous rolling of long strips of sheet metal to bend it into a desired cross-section. The strip of sheet metal passes through a set of rolls typically mounted on two stands.

Each set of rolls performs an incremental part of the bend until the ideal profile is achieved.

Roll forming is a simple process that can produce complex shapes. It is often a cost-effective and responsive alternative for press braking and stamping.

THE IMPORTANT THING ABOUT THE ROLL FORMING PROCESS:

Works on the continuous coil

No limit to the length of the bend

Bends must all be in the same direction

Profiled lengths are cut to size after forming

Tooling can be expensive

The roll forming line needs to be set up by an experienced operator

Roll forming performs best for projects that require medium to high volumes

TYPES OF ROLL FORMING MACHINES

Single duty roll forming machines: Uses strategically positioned rolls to work on a specific cross-section of the profile connected to each spindle.

Standardized rolling machines: Uses outbound supports that are easily accessible to operators. The spindle can easily be removed.

Side-by-side machines: They accommodate multiple profiles that contain various rolling tools.

Double-headed machines: Contains two separate sets of rolling shafts and housings.

Rafted machines: Has housings and spindle shafts with common rolling tools mounted on them.

ROLL FORMING ADVANTAGES COMPARED TO PRESS BRAKING

The press brake is flexible and very versatile. Almost any bend can be put in, in practically any orientation.

Metal roll forming works on long lengths of coiled material but Brake Press material must be sheet This causes it a process for higher volume production while press braking is more of a low-to-medium volume process.

Roll forming tooling costs are higher compared to other forming services

Roll forming allows for more in-line fabrication, medium to large runs, higher volume orders

More gradual forming sequence, roll forming produces extremely tight tolerances, as well as an attractive finish

The roll forming process, allows you to add tooling to create any shape, no matter how complex. Complex profiles can change easily form through the single-pass linear roll form process.

Roll forming easily handles high volume orders and is more cost-effective at high volumes

In addition to production efficiency, keeping part quality is critical to any customer delivery.

4 FACTORS TO CONSIDER WHEN CHOOSING A FABRICATION METHOD

Here are four things to consider before choosing between press braking and roll forming.

LENGTH

The length of your parts is essential to the fabrication method you choose.

Longer parts are best used with roll forming over press braking. This is because press braking cannot handle the manufacturing of longer parts.

Press braking material has to be split, sheeted and cut to length before it can be entered into the press brake. Long parts such as slit coil can be added directly into the roll forming line.

METAL FABRICATION DESIGN

Consider your fabrication design and the shapes you’ll need before you choose a fabrication method. Press braking and roll forming follow different processes, and each process has varying lengths of time depending on the complexity of the shapes you’re bending.

For instance, press braking can only handle a certain amount of bends, and each one requires a separate hit. But roll forming can form complex linear shapes in one pass, which reduces production time and costs.

MATERIAL SELECTION

Some fabrication processes do better with specific materials. The material you select can make the best of your fabrication process and may even save you money.

Press braking and roll forming can form lighter materials such as flat-rolled steel or high-strength low-alloy steel (HSLA). High-strength material is difficult to press brake and roll form.

TOOLING COSTS

Tooling costs are often the same between press braking and roll forming. The price typically depends on the type of project you are doing.

Generally, the larger the volume you use with roll forming, the less tooling costs are less expensive for each piece. If the volume is small, then press brake tooling is likely the most cost-effective option.

https://www.angleroller.com/section-bending-machine/roll-forming-machine-vs-press-brake-who-is-best-how-to-choose.html

1 note · View note