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INTRODUCTION - THE BASICS OF FLUIDIZED BED DRYING |
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The Fermented
CTC Tea is spread evenly at the feed end of the
perforated plate which is fixed onto the plenum
chamber. The Plenum chamber vibrates while hot air is
passed from beneath the perforated plate, thereby
effectively fluidizing the tea which moves forward due
to the mechanical vibration imparted to the perforated
Grid plate. The drying is completed in a single pass
in a controlled environment where the drying
temperature and discharge time may be suitably varied.
The fibre and dust particles are picked up by the dust
extraction system and collected in the cyclone. The
saturated air is removed whereas the hot and dry air
is re-circulated for better thermal efficiency.
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THE MEGAPUT – DESIGN
ELEMENTS |
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A sturdy and
robust construction with aesthetic beauty
characterizes the MEGAPUT. Needless to say, all parts
in direct contact with moisture or wet air are made of
high grade, non-magnetic, non-corrosive Stainless
Steel material only. High-efficiency hot and cold air
blowers ensure maximum power efficiency. High grade
insulation throughout the drying system minimises heat
loss thereby inducing maximum thermal efficiency.
Computer Aided Design and practical R&D have been
employed to ensure adequate control and uniformity in
air distribution and consequently in tea drying,
thereby leading to superior output quality of made CTC
tea. A centralized Console with adequate
instrumentation and multi-point temperature display
allows for easy, single - point operation.
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THE DRYING CURVE |
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TECHNICAL SPECIFICATION |
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MODEL |
MEGAPUT
D-200 |
MEGAPUT
E-300 |
MEGAPUT
F-400 |
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Capacity in Kgs./hr. (Made CTC Tea) *
(Moisture content of leaf: 62 – 76 %, Inlet temp. :
130 +/- 5 degrees centigrade) |
175 to
300 |
250 to
500 |
360 to
750 |
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Water Evaporation
Capacity (Kgs./hr.) |
400 |
650 |
1000 |
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Size of Drying Chamber
(mm x mm) |
5775L x
1100W |
7850L x
1150W |
8400L x
1720W |
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Max. Heat Load
requirement (Kcal./hr.) |
3,75,000 |
6,50,000 |
9,50,000 |
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Installed
Power** |
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A. Drying System |
16.4 kW
(22 HP) |
21.6 kW
(29 HP) |
32.5 kW
(43.5 HP) |
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B. Dust Collection |
7.5 kW
(10 HP) |
13.5 kW
(18 HP) |
18.6 kW
(25 HP) |
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Type of
Fuel |
---------------------- Coal,
Wood, Gas, Oil and Steam -------------------- |
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Fuel
Consumption (per Kg. of
Made Tea) |
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Direct Oil Fired |
------------------------------- 0.18 to
0.22 Litres ---------------------------- |
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Steam |
--------------------------------- 2.5 to 3
Kgs. ------------------------------- |
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Fire Wood |
-------------------------------- 0.6 to
0.8 Kgs. ------------------------------ |
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Coal |
-------------------------------- 0.5 to
0.6 Kgs. ------------------------------ |
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Gas |
----------------------------------- 0.15 kgs.
--------------------------------- |
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Space Occupied (mm x mm
x mm) |
9750L x 3400W x 3600H |
14000L x 3500W x 3800H |
14750L x 3800W x 4050H |
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Weight of Equipment
(without heater) in MT |
6.50 |
8.50 |
12.00 |
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* Drying
Capacity varies with moisture content of input tea,
inlet drying / firing temperature & temperature of the
ambient air.
** Installed power ratings given are recommended for
Gas Firing only. In case of Oil Firing, Installed
Power increases by 5 HP and in case of Solid Fuel
(Coal/Wood), it will increase by 10 HP. |
ADVANCED
CONVENTIONAL TEA DRYERS
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Having evolved
over time, the latest ‘Avatar’ of the Conventional MEGAPUT
is a Stainless Steel Tray Dryer with a Made Tea output of
upto 350 kgs./hr under standard CTC wither/drying
conditions.
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INTRODUCTION – THE BASICS OF
CONVENTIONAL DRYING |
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The
MEGAPUT is a versatile High Moisture evaporative capacity
Machine which has been developed as a result of constant
R&D. This Dryer is equally suitable for Black Tea (CTC &
Orthodox teas) as well as green Tea Drying.
Based on the well proven Tilting Tray theory whereby the
leaf is conveyed on slow-moving perforated trays through
the drying chamber, the MEGAPUT retains all the inherent
advantages of Conventional Drying technology in terms of
preserving the natural bloom, liqueur and taste of tea.
At the same time, a modular design,
innovative technological enhancements such as Stainless
Steel Trays, Roller chain, improved Sprocket design and a
sturdy, insulated steel housing enable the MEGAPUT to
transgress the boundaries and limitations of Conventional
Drying technology. The biggest model, M277, has a 27’ long
and 8’ wide chamber and boasts of an evaporative capacity
of 750 - 800 kgs. of water / hr. The smaller Megaputs are
designed to suit the needs of the individual customer.
The
Megaput Drying Systems are designed to induce about
1350-1500 Air Changes per Hour in the chamber. The
Drying Curve has been optimized by fixing optimum tea
travel ratios between the different tray circuits so as to
optimize drying quality.
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TECHNICAL SPECIFICATIONS |
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MODEL |
M154 |
M214 |
M156 |
M216 |
M256 |
M277 |
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Capacity (Made Tea /
hr.)
Single Firing at 72% wither*, 200-210ºF
inlet |
80-100 |
110-130 |
130-150 |
180-210 |
230-250 |
300-350 |
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Water evaporative capacity (kgs./hr.)
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180-220 |
250-300 |
300-350 |
450-500 |
550-600 |
750-800 |
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Installed Power rating (HP)
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12.75 |
13.75 |
14 |
19 |
26 |
31 |
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Inlet Drying Temp.
(ºF) |
--------------------------------------------------------------------------------------
200-210
------------------------------------------------------------------------- |
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Exhaust
Drying Temp.
(ºF) |
--------------------------------------------------------------------------------------
125-130
------------------------------------------------------------------------- |
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Air Delivery (CFM) |
11,000 |
13,000 |
15,000 |
19,000 |
23,000 |
27,000 |
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Oil/Gas Burner Size |
2A |
2A |
3A |
3A |
4A |
5A |
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‘SUPER’ Coal/Wood Heater |
12 |
12 |
14 |
14 |
14 |
16 |
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Oil Consumption (Direct Fired) |
---------------------- 0.23 – 0.25
litres / kg. of made tea ----------------------- |
------------ 0.20 – 0.22 litres / kg. of
made tea ------------ |
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Coal Consumption (Indirect Fired) |
----------------------- 0.60 – 0.75
kgs. / kg. of made tea ----------------------- |
-------------- 0.4 – 0.5 kgs. / kg. of
made tea -------------- |
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Tray Construction |
--------------------------------------------------
Mild Steel, Tin Coated -------------------------------------------------- |
--------- Stainless Steel -------- |
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* 72% wither indicates
removal of 28 kgs. of water from 100 kgs. of Green Leaves
during withering. In case of Orthodox teas at 55% wither
and 210-215ºF inlet temp., Dryer Made Tea output Capacity
will increase by roughly 30 – 35 %
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'MEGAPUT' FEATURES |
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VERSATILE
The Megaput comes in varying sizes
and is equally suitable for drying CTC, Orthodox and Green
Tea. The Megaput is available in a series of customizable
Tray designs and throughput times to suit every drying
application.
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ECONOMICAL
With a power consumption of 31 HP, a
coal ratio of 0.4-0.5 and an output of upto 350 kgs./hr.
under standard CTC wither / drying conditions, the M277
Megaput offers unprecedented economy in drying tea. The
smaller MEGAPUTs offer similar economies.
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COLD FEED SYSTEM
The MEGAPUT is equipped with a heavy
duty Cold Feeder Tray system with customizable length. The
slope of the feeder is designed to ensure ZERO slip-back
of tea.
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SPREADER
The Cold Feeder is equipped with a
Revolving height-adjustable Main Spreader Unit which is
inter-linked with an Auxiliary Spreader in the top
circuit.
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VARIABLE
SPEED DRIVE
The Machine is driven through a
time-tested and compact Variable Speed V-Pulley reduction
Gear unit.
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GLASS WOOL INSULATION
The Dryer panels are provided with
double-walled glass wool insulation to prevent heat loss
and increase thermal efficiency. The large inspection
doors, provided for easy supervision, are fitted with
heat-resistant glass to minimize heat loss from the drying
chamber.
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SAFETY DEVICE
All Megaput Dryers are
quipped with a built-in Safety Device System to check tray
jamming and eliminate motor burn-out.
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TRAYS, CHAINS & SPROCKETS
The M277 employs Stainless
Steel Trays with Roller Chain drives to maximize hygienic
drying and minimize wear & tear. The other Megaputs have
heavy duty Tin Coated trays made from 16 gauge sheet with
Roller Chain drives.
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BEARINGS
The
Drying chamber has been provided with standard MSC, MSF
and MST type Ball bearings to enable the shafts to carry
relatively heavy thrust loads.
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FLOOR SCRAPPER
The
Megaput is equipped with a tray-based conveyorised floor
scrapper system to optimize tea recovery and enhance
overall drying quality.
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CENTRIFUGAL FAN
The
Megaput is provided with an Indigenously developed Double
Inlet Hot Air
fan, produced in-house with dynamically balanced rotors.
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