The Double Belt Press and Its Alternatives
So you want to know about a belt press machine—and not just that, but the variations of a belt press machine. Like, for example, a double belt press. This equipment can be extremely important. Depending on the type of project you’re working with – the more you know, the better. Here’s a quick breakdown of what you need to know about this machine and its processes.
What is a belt press machine?
Perhaps, you’ve heard of a belt press machine before—though you may have heard of it referred to as a belt filter press. Either way, the role of a belt press machine is to remove water from liquid wastewater residuals. After that, they produce a non-liquid substance, which we refer to as “cake”. It’s a simple process on paper, though of course we may find it a little more complicated in practice. Why do we take this extra step (you’ll hear it referred to as “dewatering”)? Because it’s important.
We dewater these residuals because the process reduces the overall volume of the residuals, shrinking them in essence. This makes operations a bit easier and less effortful, while also reducing the amount of space the residuals take up—you can use that space for other, more valuable storage purposes. It’s also simpler to process residuals this way, and we can say the same of transferring them, disposing of them, and making end use of them.
Essentially, a belt press works in separating a liquid from a solid. On a practical level, what would you rather deal with? Sludge, which is much messier and can go anywhere (contaminating other products and processes)? Or a solid, which is neater, easier to control, and confined to a single space (as opposed to spreading, as sludge usually does)? The answer is clear. With that in mind, a belt press machine can be rather valuable.
How does a belt press machine dewater residuals?
The basics of the dewatering process go like this: we use pressure to squeeze the liquid from the solid. More specifically, we pass chemically conditioned solids and press them between two porous tension belts. Subsequently, we pass those solids over and under different rollers, which vary in terms of their diameters. This process increases the pressure over time, and the rollers decrease in diameter. Ultimately, this results in the separation you’re looking for from dewatering.
What are the different types of belt presses?
Now, there isn’t one single type of belt press machine. Different variations on the equipment serve different purposes, which means you’ll be able to find a machine that fits your specific needs perfectly.
The most obvious variation between belt press machines lies in the amount of belts. These machines are available in one-belt, two-belt (double belt press) and three-belt (triple belt press) forms. Additionally, the double belt press can come in an extended gravity design. This has a longer gravity drainage zone. The triple belt machine already has its own independent gravity zone, which offers a more open belt, resulting in a more rapid drainage of the water.
What do the different “zones” do?
In general, most belt press machines have three clearly delineated zones:
- The gravity zone. This zone uses gravity to drain free water via a porous belt.
- The wedge zone. Here, we prepare solids for the application of pressure.
- The pressure zone. The belt press uses this zone to apply medium to high pressure to conditioned solids.
When you work with more advanced belt press designs, you may also find additional features like a larger filtration area, additional rollers, and variable belt speeds capable of increasing cake solids. The great thing about these different variations is that they enable you to customize the process a bit more. No matter what kinds of products you’re working with, and what your needs, you’ll find a belt press machine that suits your purposes perfectly.
What are the advantages of using a double belt press machine?
In some ways, you can see a double belt press as a compromise between the simpler one-belt design and the more complex three-belt design. Its advantages are clear. A double belt press machine works more quickly and efficiently, without bringing in the variable of the extended gravity design (which won’t work for every situation).
What if I don’t own the proper equipment?
If you don’t have a double belt press—or a belt press machine in general—on hand, don’t worry. You’re quite far from being alone! While some business owners wish to invest in their own equipment, others prefer to collaborate with a third party manufacturer. The manufacturer owns the equipment and creates the final product or provides the required service. Depending on what kind of third party you work with, they’ll offer clients a degree of involvement—but you can choose which service works best for you.
The two main types of third party manufacturing typically utilized are contract manufacturing and toll manufacturing. With contract manufacturing, the third party handles the process from beginning to end. You’ll sign a contract, and the third party, while discussing formulation and processes for you, will effectively handle everything. Toll manufacturing, however, enables you to provide the raw materials involved, which gives you a bit more control.
No matter which process works best for you, CTI is here to help or simply offer advice. Call us at 419-924-5566 or contact us here for more resources. We’re happy to help!
Keep in mind, there are also many tasks that we can do for you such as:
- Apply adhesive coatings
- Slitting and Die Cutting
- Hot Melt Spray Coating
- Slot die coating
- Hot gravure
- Powder coating
- Web Coating
- Belt Laminator
- Roll coating
- Hot roll lamination
- Water-based gravure coating and printing
- Meyer rod coating
- Knife-Over-Roll coating
Again, let us know if we can help with your manufacturing needs. We look forward to hearing from you!