Customer:

Contact(s):
Date:
ETI Contact(s):
Subject:

Mxico EL PEDREGAL
J. Almazn, M. Bello
May 21rst, 2015
S. Stapleton, C. Paredes
Findings from Service Courtesy Visit May 19 th to 22nd 2015.

Visit Report
Customer Info:
ETI Project No: 98B001

44x36 Live Bin

6x84 Screw Feeder
10x72 DCC Conditioner Cylinder
7 Head LH E525A Extruder
521 AFl Dryer 1 w/plastic mesh

Customers Expectations:
I. Have ETI techs do a thorough walkthrough around the plant, and hold a Wrap-Up meeting to
address all the findings.
II. Customer would like to improve current production rates on the E525 extrusion system. ETI to
evaluate what must be done to achieve this important goal (Enhanced barrel configuration,
additional drying sections, etc.)
III. Customer would like to install a LIW and a Full Automated Control System on their existing
E525 extrusion line.

Information Extru-Tech will need from El Pedregal

Current Feed Rates when producing 0.6mm, 0.8mm, 1.0mm and 2.1mm pellets.
What is the Amp Loads on the extruder main motor, when running 0.6mm, 0.8mm, 1.0mm and 2.1mm
pellets.
Current number of Holes in the 0.6mm, 0.8mm, 1.0mm, and 2.1mm Die Plates.
What are the Drying Temperatures & % Moisture out of the Dryer for 0.6mm, 0.8mm, 1.0mm and
2.1mm pellets.

Plant Walkthrough & Findings

Grinding, Mixing & Sifting

Customer is adding liquids at the mixer & before sifting. NO liquids are being added at the Conditioner Cylinder
Possible problems: Plugged sifters, variations in the density of the meal in one same lot, before Extruders Live
Bottom Bin, etc.

10x72 DCC Conditioner Cylinder

Steam pressure to the Conditioner found to be at 80psi.

No AVT!
DCC being rinsed every 4 months and NOT Once per week
Beater Configuration found to be Old standard and may be enhanced.
E525A Extruder

Found water inside Bearing Housing. Also found wrong type of oil has been used.
Found old quill assembly with extensive level of wear. (See Pictures 1 & 2)
Found extruder shaft worn extensively on Shoulder Section (See Picture 3)
Found plugged vent in Bearing Housing
Found locally made screws being used (See Picture 4)
Found re-machine threads and cone bolt larger in diameter
Found straight liners being installed. ETI currently is sending extruders with ALL spiral liners.
Found new and worn knife blades were being used at the same time. When this is done, you
have larger linear space between the knife cutting edges, and your product may have
inconsistent lengths. (See Picture 9)

Extruder found running WITHOUT a Front End Shaft Support Assembly.

Steam pressure to the Barrel found to be at 25psi.

(See Picture 5)

521 Dryer with Mesh

Old style of spout spreader chute was found. (See Picture 6 & 7)
Air Filters on the Gas Burners were found plugged (very dirty with lots of dust)
Plastic mesh was found very clean

(See Picture 8)

Increase Current Production Rates (Kgs/Hr.)

Install a larger DCC like a 16x72 model.

Need to install new Bearing Housing, New Shaft, all new Screws and all new Liners
Install a larger size extruder motor (from 125HP and go up to a maximum of 200HP)
New Enhanced Proposed Extruder Barrel configurations (See Picture 10)
Install two additional drying sections and one additional cooling section.
Sign-Up for ETIs ESP program and provide an On-site Training course for all of your
production, maintenance and QC teams.

Automatic Control System with LIW (Loss In Weight)

Increase the height of the Elevator Leg that fills the extruders Live Bottom Bin (need to confirm
dimensions)

Look into alternatives to re-locate your extruder, from where it is now. (See Picture 11, 12 & 13)
Graphic Support
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