Aarkay's 'ULTIMA' CTC Machine


‘ULTIMA’ CTC MACHINES THE 'ULTIMATE' CTC MACHINE Launched in the new millennium after years of R&D, the 'ULTIMA' epitomizes Aarkay's commitment to balance quality and cost. A vibration - free and sturdy construction, modular design, cooler cuts, higher percentage of Brokens, longer life of bearings, reduced power consumption, and a spillage - free performance is what makes the 'ULTIMA' truly the numero uno in its class. Available in various models from 24" to 52" in width and 8.5" to 13" in roller diameter, the ULTIMA has a versatile design to suit the various needs of the discerning consumer. The 'ULTIMA' is also the first and only CTC machine in the world to be available in both Straight Pedestal and Inclined Pedestal versions with a standard/uniform machine and component structure.
'ULTIMA' FEATURES
HEAVY & ROBUST CONSTRUCTION The 'ULTIMA' employs superior Alloy Grade castings for pedestals, duly re-inforced, for higher rigidity and vibration - free performance.
LOW HEIGHT The low height of the 'ULTIMA' allows for easier and better supervision. Roller changing has become faster and easier, leading to ease in maintenance activities. The low height also enables vibration - free and reliable performance.
INTERCHANGEABILITY Computer - Aided Design and precision engineering enables interchangeability of H.S. and S.S. rollers as well as any parts between the different cuts.
CASTING LIFE & MAINTENANCE All Cast Iron parts are made from superior quality Graded Castings for better durability and heat resistance. As there are no moving parts, very minimal maintenance is required on a regular basis except for cleaning of tube banks. Provision of conveniently placed Cleaning and Soot removal doors at the front and rear ends facilitate easy tube cleaning, soot removal and casting inspection.
BEARING HOUSING & ROLLER CHANGING The 'ULTIMA' incorporates a unique Spring Loaded Housing System that nearly doubles the life of the bearings while ensuring uniform cutting of the tea leaves by acting as a 'shock absorber' for the bearings and allowing for automatic correction in case of bearing wear. As a standard option, the regular Cartridge type Bearing Housing may be employed. Hardened bearing sleeves have been provided in the 'ULTIMA' as a standard feature for faster and smoother roller changing.
HYDRAULIC 'CONTINUOUS' MOVING COVERS The hydraulic mechanism introduced in the 'ULTIMA' for lifting the moving covers allows for easier access to the belly of the cutting units for regular cleaning which is essential to avoid bacterial contamination. The Moving covers have continuous free movement, unlike the cumbersome ratchet and pawl design of the older machines.
REDUCED POWER CONSUMPTION Installed power rating has been brought down by 5 HP per cut. A sturdy machine design with heavy duty bearings, and incorporation of auto-dejamming and auto-tripping as standard features have enabled this reduction in both installed and actual power consumption, leading to huge savings in the annual electricity bill.
DRIVE Positive drive heavy duty Gear Box is fitted with hardened shafts, gears and heavy duty bearings for longer life and easier drive. Heavy duty propeller shafts are used for instant and zero spillage propelling of rollers.
COOLER CUTS Bigger gaps between rollers and conveyor belts allow better air entry in the cutting units. An efficient cooling system with a dynamically balance centrifugal cooling fan and ducting connections to each cuts has been provided for cooling the teas.
HYGIENIC FEATURES Moving covers with hydraulic lifting systems, use of imported food-grade PVC belts, and specially designed detachable Stainless Steel side guards enhance machine hygiene by not allowing tea accumulation in the inaccessible areas and thereby effectively eliminating the bacterial menace. Unlike static covers where the cut 'mal' gets deposited on them and thus make them the mother-bed of bacteria, the moving covers with imported PVC belts do not allow any deposit or accumulation of teas. There is also no lump or ball formation. Based on the experience that with 40" PVC belts, the full cutting area of the 36" CTC Machine cannot be used and that this causes side spillage, wider and non-sticky food grade PVC belts are provided for hygienic and longer life. Hence, in a 36" machine, 42" wide belts are used.
AXIAL PITCH ADJUSTMENT Matching of HS and SS Rollers is vitally important. Axial pitch adjustment has been made simpler for easy matching.
MICRO MESHING Meshing of rollers with micro-fine tuning of cutting has been incorporated with simple and error-free adjustment. After having adjusted microdial matching on both ends, just synchronize Micro adjustment for cutting with the knob, which is very easy to operate.
IMPROVED CLUTCH SYSTEM A simple and operator - friendly clutch system has been introduced in the 'ULTIMA' for engaging and dis-engaging moving of conveyor belts within a fraction of a second.
IMPROVED DEJAMMING AND AUTO - TRIPPING An improved de-jamming system and auto-tripping have been incorporated in the 'ULTIMA' as standard features to protect rollers and electrical motors and to achieve immediate re-instatement and same matching / meshing.
LOW INCLINATION OF CONVEYOR BELTS The 'ULTIMA' design incorporates a low 14 degree inclination of conveyor belts. This prevents roll-back and tea deposition on the sides, provides more gap for ambient air in-flow, and allows for zero ball or lump formation.
ZERO SPILLAGE AND ZERO-TRACKING The specially designed SS side-guards, wider conveyor belts and and the low inclination of the Conveyor Belts have all been designed to make the 'ULTIMA' virtually a Zero Spillage machine. Special ribbed Zero-tracking Conveyor Belts with grooved conveyor rollers have been employed to completely eradicate the issues of belt-slippage and folding, thereby eliminating wear and tear of the belts and guaranteeing zero side spillage.
VALUE ADDITION IN INPUTS The Machine Pedestals are the heaviest in the Tea Industry. All the contact points with tea are made of AISI304 grade Stainless Steel material only. The Dejamming Handle, Clutch lever, Microdial, Micro - mesh arrangement, ratchet, etc. are all either hard-chromed or made of Stainless Steel, precision engineered and painted with long lasting paint with silken finish. The aesthetic and refined looks of the 'ULTIMA' and its eye-catching appearance is guaranteed to captivate your senses. All electricals are outsourced from the world leaders in the field such as Greaves and Siemens. This is one machine where the word 'compromise' does not figure in the details or the description.
TRULY FLEXIBLE AND MODULAR The 'ULTIMA' is the first and only CTC machine in the world to be available in both Straight Pedestal and Inclined Pedestal versions with a standard/uniform machine and component structure. It may be purchased in configurations of one to six cuts as per the nature of the tea and the purpose of the operation. The Machine itself is available in various sizes such as 24", 30" 36", 38" and 42" in the Standard (8.5") and Medium (9.5") models, as well as 24", 30", 36", 38", 42", 48" and 52" in the Jumbo (13") model.

TECHNICAL SPECIFICATIONS & DATA
OVERALL DIMENSION
MODEL	ULJ30			ULS/M 30			ULJ36		ULS/M 36
	3 cut		4 cut	3 cut	4 cut		3 cut	4 cut	3 cut		4 cut
Length (mm)	10481		13122	9908	12346		10481	13122	9908		12346
Width (mm)	2245		2245	2245	2245		2400	2400	2400		2400
Height (mm)	1090		1090	1040	1040		1090	1090	1040		1040
Output (GL/hr)	1000 - 1100 kgs.			800 - 900 kgs.			1100 - 1200 kgs.		1000 - 1100 kgs.

HORSE POWER (RECOMMENDED)
MODEL	ULJ30			ULS/M 30			ULJ36		ULS/M 36
Normal	20-15-15-15			15-15-15-15			25-20-20-20		20-15-15-15
Hard Cut	25-20-20-20			20-15-15-15			30-25-25-25		25-20-20-20

CONVEYOR BELT (IMPORTED)
MODEL	ULJ30			ULS/M 30			ULJ36		ULS/M 36
	Width (mm)		Length (mm)	Width (mm)	Length (mm)		Width (mm)	Length (mm)	Width (mm)		Length (mm)
Feed	900		4876	900	4876		1050	4876	1050		4876
Subsequent cut	900		6096	900	5790		1050	6096	1050		5790
Moving Cover	900		2030	900	1830		1050	2030	1050		1830

ROLLER SHARPENING DATA
Roller		Diameter		Tilt Angle º		Cutter Angle º		Helical		Chasing Profile
13"		8 T.P.I.		45.6		65		80		55º / 45º
		10 T.P.I.		45.6		65		96 - 100		55º / 45º
9.5"		8 T.P.I.		52		65		60		55º / 45º
		10 T.P.I.		52		65		70		55º / 45º
8.5"		8 T.P.I.		47		70		50		55º / 45º
		10 T.P.I.		47		70		60		55º / 45º

SPEED
MODEL			ULJ (13")			ULM (9.5")			ULS (8.5")
			Motor RPM = 1500			Motor RPM = 1500			Motor RPM = 1500
H.S. Roller			550			630			720
S.S. Roller			55			63			72
Gear Box ratio			10:1			10:1			10:1
NOTES: Conveyor belt can be provided long or short as per requirement and space availability. Discharge belt length may vary as per requirement. Recommendations given above are subject to various factors such as leaf quality and type of cuts. In view of commitment to continuous research, development and product improvement, specifications may change from time to time.