Processes and Applications

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The most common application group for the Berndorf Solid Steel belt heat processor is in the manufacture of continuous slab, sheet or film products by converting of a liquid, paste or powder material into a solid product. Some type of heat processing such as drying or polymerizing is involved, but the primary objective in these applications is to create a slab, sheet or film product. For this reason the systems for these applications are often referred to as casting lines, foaming lines, or film casters. Some typical applications are:

Reconstitute tobacco sheet: Formed on a steel belt from a slurry containing tobacco scrap and dust. The sheet is used as a cigar wrapper or binder or chopped up for use as a cigarette filler when blended with chopped leaf.
Solution cast plastic films and sheets: Products include polyvinyl chloride, polycarbonate, cellulose triacetate (TAC), polymide, polyvinyl alcohol (PVOH), and polypropylene. Other examples occur in the production of synthetic microporous filter membrane used in dialysis and reverse osmosis equipment, production of ceramic sheet for the electrical industry and in the manufacture of polyester resin (imitation marble panels).
Rubber products: Includes drying and curing of extruded rubber profiles for the automotive industry, drying and curing of foam rubber slab for athletic protective wear, wet suits, and carpet underlay as well as latex rubber sheet for medical use.
Sintering of plastic polymers in powder form to produce porous sheets and slabs for use in filtration and fluidization equipment, energy cells, and automotive batteries.
Bakery and other food products: The steel belt is particularly advantageous when handling sticky materials. Products include cookies, cakes, scotch breads, English muffins, crepes and pet foods.
Chemical products: Diverse group includes filter press cake, particularly significant for high value materials such as precious, semi-precious or exotic materials and metals, iron hydroxide for magnetic tapes, dyes and pigments, tungsten oxide, and various other products where agitation during processing would be detrimental.

	System Configuration Your system will be designed to accommodate the multiple processing needs of your product. We utilize large pulleys to ensure product flatness and equalize bands of distribution. Equal air distribution both above and below the steel band along with split air flows of varying temperatures and velocities can be achieved. It is possible to obtain different air velocity, temperature, humidity, heat transfer and mass transfer rates all within the same system. Split airflow can also utilize heat recovery to reduce BTU consumption and utility costs.
	Heating Processes A solid steel belt is an excellent conductor of heat, ensuring even distribution and temperature control. Berndorf steel belt systems can accommodate any type of heating process including drying, curing, gelling, sintering, polymerizing, vulcanizing, reacting, baking, cooking or any other process involving heat. Our systems achieve uniform heat transfer with the use of spray nozzles that are located above and below the belt in a solid overlapping pattern. Our high efficiency designs and high capacity systems allow you to process your product quickly and efficiently.
	Cooling Processes The Berndorf solid steel belt conveys the product over cooling tanks where the underside of the belt is spray cooled with water that is collected and recirculated to a cooling tower or chiller. The spray nozzles are a solid overlapping pattern to assure uniform heat transfer. The spray cooling tanks can be divided into zones having different water temperatures for profile cooling of sensitive products. Overhead air hoods may be included using conditioned or ambient air and the entire Berndorf cooling system can be designed explosion proof.
	Drop Feed This system is the most versatile conveyor feed system on the market today with the ability to deposit drops in sizes and production rates based upon product testing in our test center. We will provide you with a uniform sized, attractive and ready-to-package product while eliminating secondary cutting and crushing operations.
	Weir Sheet Feed This system applies products onto the belt via a method called "controlled overflow." In conjunction with the belt speed, a Weir Feed allows you to control the thickness of the deposited product within close tolerances and with the greatest of ease.
	Strip Feed The Strip Feed is ideal for depositing parallel bands of a variety of materials onto the belt surface. Stable, constant pressure insures consistency as well as uniform width and depth of every product strip
	Squeeze Rolls The Squeeze Roll system utilizes two rollers to create a sheet from compound resin fed from an extruder. Water-cooled jacketing, along with a choice of surface coatings prevents your product from sticking on the roller surfaces. Discharge Product discharge will depend on the processed product's format. If a product discharges as a continuous sheet, it may require slitting or cutting. Other products may require separation from the belt using a scraper or crusher. Still others require a simple discharge because product shape is formed in the feed.
Berndorf Belt Systems is a customized, application-driven, solutions provider. We have a full test center at our headquarters in Elgin, IL where we can test your product and make necessary modifications before we manufacture your system. We will work with you on the complete design, engineering, budgeting and manufacturing of your process conveyor system as well as system components including feeding devices, belt guidance systems and accessories. Berndorf Belt Systems is your partner for the life of your system. We have experts accessible throughout the world to accommodate your maintenance and repair needs. Our engineers and staff, experienced in working with a wide range of industries, are able to troubleshoot and quickly repair problems. We have a large inventory in stock which can normally ship overnight. This means less downtime and reduced maintenance costs. Berndorf Belt Systems is proud to be an industry leader with a global perspective. For the last 25 years, customers around the world have relied on Berndorf steel belt conveying systems. Since the early 1900’s, customers have relied on Berndorf steel belts. From our parent company's home in Austria, to our home in the United States, Berndorf customers receive our commitment to a long-standing, beneficial relationship. Berndorf — your full solutions provider for the future.

Berndorf Belt Systems USA • Berndorf Belt Technology USA
2525 Bath Road • Elgin, IL 60124
United States
US Phone: 1-800-393-8450 • Intl Phone: (1) 847-931-5264 • Fax: (1) 847-931-5299 • sales@berndorf-usa.com
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