Everything You Need to Know About S20 Flair & Quadro Comil

Everything You Need to Know About S20 Flair & Quadro Comil

High Efficiency Milling (HEM) is a modern machining strategy designed to maximise material removal rates (MRR) while minimising tool wear and heat generation. HEM involves using a lower Radial Depth of Cut (RDOC) and a higher Axial Depth of Cut (ADOC). This approach spreads wear evenly across the cutting edge, dissipates heat more effectively, and reduces the likelihood of tool failure.

The technique offers several benefits such as:

Increased tool life due to even wear distribution

Higher material removal rates due to aggressive cutting

Reduced heat generation due to lower RDOC and higher ADOC

Cost efficiency due to longer tool life

Faster machining times

HEM is particularly useful in industries where efficiency and precision are critical, such as aerospace, automotive, and mold making. It is suitable for a wide range of materials, including aluminium, steel, and titanium.

High Efficiency Milling vs. Traditional Milling

Traditional milling typically uses a higher RDOC and lower ADOC, which concentrate heat and wear on a smaller portion of the tool, leading to quicker tool degradation. HEM, on the other hand, uses more radial passes and fewer axial passes, maintaining a constant load on the tool throughout the operation. Many Computer-Aided Manufacturing (CAM) software packages now include modules for generating HEM toolpaths. These modules often go by different names, such as Dynamic Milling or High Efficiency Machining. They are designed to optimise the milling process by maintaining a consistent chip load on the tool.

Key Factors for the Success of High Efficiency Milling

To successfully implement High-Efficiency Machining (HEM), a fast CNC controller is essential to handle the complex toolpaths generated. High-performance end mills designed for higher speeds and feeds are crucial for optimal performance. Proper parameter optimisation, including adjusting feed rates, speeds, and depths of cut, is vital to maximise the benefits of HEM.

Now, let’s take a closer look at two of the well-known high-efficiency milling equipments from IDEX. The S20 Flair and Quadro Comil.

The S20 Flair

The S20 Flair is a high-capacity rotary sifter designed by Quadro, a part of IDEX Corporation. It’s primarily used for screening and deagglomeration of powders in various industries, including pharmaceuticals, food, cosmetics, and chemicals.

The S20 Flair uses rotary sifting technology, which employs centrifugal force to push product particles through a mesh, effectively separating impurities and foreign materials. This sifter includes a unique in-process cleaning feature that purges perforations, ensuring uninterrupted processing and minimising product retention.

The S20 Flair offers several benefits, including up to an 80% reduction in sifting times compared to traditional vibratory sifters. It is easy to maintain due to its minimal number of parts and a single bolt locking mechanism for quick screen changes without special tools. The user-friendly design features a motorised height-adjustable stand and HMI-based controls for easy operation.

The S20 Flair has a wide range of applications. In the pharmaceutical industry, it ensures safe processing of pharmaceutical powders, meeting FDA and cGMP standards. It is also suitable for screening and de-agglomeration of difficult-to-handle powders in the food industry. The S20 Flair is also used in the cosmetics and chemicals industry for efficient powder-sifting capabilities with nearly 100% product recovery.

The S20 Flair is available in various mesh sizes, ranging from 6.0 mm to 0.225 mm, to suit different applications. Its compact design allows it to fit below most bulk bag unloaders and mixer discharges, making it versatile for various setups.

The S20 Flair offers several advantages over traditional vibratory sifters. It significantly reduces dusting, minimising airborne fine particles and limiting operator exposure. The S20 Flair also enhances overall productivity by providing seamless sifting and reducing product waste.

The Quadro Comil

The Quadro Comil is a versatile conical screen mill that efficiently reduces particle size and deagglomerates materials in both dry and wet forms. Its conical screen and rotating impeller design ensures consistent particle size distribution, making it ideal for various industries.

Key benefits of the Comil include:

• Consistent particle size distribution: Ensures product quality and process efficiency.
• Versatility: Handles a wide range of materials, from dry powders to wet granulations.
• Scalability: Available in various models to suit different production needs.
• Easy maintenance: Designed for easy disassembly and cleaning, minimizing downtime.

The Quadro Comil is a reliable and efficient solution for particle size reduction and deagglomeration in various applications.

The Comil has a wide range of applications. In the pharmaceutical industry, it is used for sizing wet granulated particles before drying and sizing dry granules before tableting. In the food and beverage industry, it is ideal for deagglomerating dried fruits and reclaiming broken biscuits. In the chemicals and cosmetics industry, the Comil is suitable for bulk density adjustment, mixing, and dispersion.

The Comil is available in various mesh sizes to meet specific application requirements. Models range from lab-scale units to high-capacity production units capable of processing up to 120,000 lb/h (54,500 kg/h) for certain products.

The Comil offers several advantages over traditional mills. Its design ensures high efficiency and low heat generation, making it suitable for heat-sensitive materials. The Comil also offers greater application versatility with options for both overdriven and underdriven configurations.

The Comil is available in both overdriven and underdriven models, with the motor located above or below the milling chamber, respectively. This offers different benefits in terms of space and maintenance. The Comil also features various impellers and screens to customise the milling process for specific materials and desired outcomes.

Conclusion

High-Efficiency Machining (HEM) is a valuable technique for maximising material removal rates and minimising tool wear. HEM, combined with advanced equipment like the S20 Flair and Quadro Comil, offers significant benefits in terms of efficiency, productivity, and product quality. By understanding the key features, applications, and benefits of these technologies, businesses can optimise their manufacturing processes and achieve superior results.