The DiscMaster™ Spraying System
The DiscMaster™ series of Spraying Machines have been designed as the versatile system of choice for small to medium scale business. It provides the important economies of scale and manufacturing flexibility that such operations demand. High operational up time is achieved by the blockage resistant spray delivery system, which coupled with easy maintenance access, minimises downtime and delivers a quick ROI for business managers. Transportable on castors for easy relocation within the factory, it can be used as either a stand-alone offline unit or integrated into a small production facility.
Configured during manufacturing to provide Top, Top & Sides or All Over Full Spray Coverage, these machines utilise the same proven spinning disc spray technology, previously associated with professional level equipment. For operation at temperatures other than ambient, the heating/chiller packs can maintain the unit at the appropriate temperature for either heated or chilled spraying operations.
Operationally, the DiscMaster™ offers repeatable precision in the application of spray material, previously unavailable at this investment level. Precision Inverter/Motor Control Systems provide digital control to the Spinning Disc Speed, Pump Speed and the Conveyor Speed, allowing full control over the droplet formation and deposition of the spray material. Recording the setting of the digital potentiometer for each of the key control systems provides a unique digital signature for each machine set-up. Product changeovers can be quickly accommodated by entering the signature code into the machine for the appropriate machine configuration. The precision accuracy inherent in the system ensures it correctly returns to an identical set-up as the last batch of that particular product. A proportion of the pump output is returned directly to the reservoir tank, which provides:
- Improved precision in the control of the spray application rate
- Continuous re-circulation which inhibits the separation of emulsions
- Enhanced temperature stabilisation of the spray material
DiscMaster™ Spraying System Schematics
Operational Benefits
High Quality Output
- Saturn offers bespoke manufacturing solutions that are based on our patented spinning disc technology. Since it is a bespoke solution, there are no compromises or workarounds that can affect the dynamics of the production system. We are able to provide varying degrees of product coverage from ‘Top Only’ to ‘Total Coverage’, within our product range.
Full Product Coverage
- We provide a full range of products that accommodate coverage options from ‘Top Only’ to ‘Total Coverage’. The desired product spray can range from single disc machines that give single side coverage to a product; to multiple discs that can be positioned above and below the product conveyor line and angled to provide desired total product coverage.
High Throughput
- Saturn’s systems can maintain a consistent, even density of product coverage, even with higher conveyor speeds. The spinning disc technology that is a nozzle-less application method is resistant to those frustrating, unscheduled line stoppages necessary to cope with the blockages and uneven spread patterns experienced elsewhere. The aperture in a spinning disc system is 6.0 mm.
- Precision, control, quality and reliability are essential components in modern manufacturing dynamics; the system’s synergy ensures a speedy return on the capital investment.
Quick Product Changeovers
- Incrementing/decrementing the code on the digital potentiometers alters the performance of the system’s conveyors and pumps to the individual level required. On a non-dedicated production line, our precision incremental control ensures perfect re-registration of the system set-up from one production batch to another.
Protecting the Environment
- In order to achieve greater product throughput, nozzle spraying systems often need to use higher line air pressures to maintain the cover density. Unfortunately, there is a hazard of spray atomisation that requires careful control and even on occasion expensive extraction equipment to maintain a safe work environment.
- Saturn’s patented spinning disc technology has none of these drawbacks and is often seen as the safe, environmentally friendly, spray coating system to choose for modern work environments.
System Construction
Built as a single integral unit with removable access panels and stainless steel pipe work, the DiscMaster™ is designed for ease of cleaning and maintenance. When configured for both top and bottom spraying the minimum working height of the conveyor belt will be 1050 mm. The Standard Disc Motor supplied is an IP66 Stainless Steel which provides a high level of water protection with an excellent cosmetic finish. It allows for easy cleaning as well as ease of maintenance
The width of the machine can be selected to suit either the application or the existing conveyor belt width. The machine series can accommodate line widths from 300 mm to 700 mm. The maximum number of spray heads on the top is four with two spray heads fitted underneath.
The standard length of the machine is 1000 mm, but the in-feed and out-feed can be extended as required to meet system installation requirements {see 'Extended Conveyor' section below}. Conveyor belts can be either stainless steel wire enrobing for loose product or chain drive for trays. The maximum belt width available with the DiscMaster™ series is 700 mm.
System Configuration Options
Low Sensor Level & Beacon
A visual warning by an amber flashing beacon indicates that the reservoir requires topping up. The beacon is associated with a reservoir level sensing device that triggers the beacon when the level of the reservoir falls below a recommended level.
Extended Conveyor
When used in a standalone offline configuration, extending the length of the conveyor in-feed and out-feed sections allows trays and/or loose products to be loaded and off-loaded with ease.
Conveyor Snub Nose
Snub Noses extensions on either the in-feed or out-feed conveyor section provides one of the versatile interface requirements for mating with adjacent conveyor systems. Below is a 100 mm Snub Nose extension on the out-feed conveyor, choosing the appropriate Snub Nose diameter is important in the product transfer.
Conveyor Mist Covers
This option is highly recommended when the machine is used for the spraying of oils. The covers provide a simple mechanism to reduce the entry aperture of the spraying machine to the minimum clearance necessary for the product to transit the machine. This effectively contains any misting within the body of the machine. Oil mist falls out of suspension and is recycled through the machine as normal.
Sealed Stainless Steel IP66 Disc Motors
The Standard Disc Motor supplied is an IP66 Stainless Steel which provides a high level of water protection with an excellent cosmetic finish. It allows for easy cleaning in place {CIP} as well as ease of maintenance. As an option, an IP54 Cast Aliminium body motor is available.
System Materials
The machine is constructed in stainless steel grade 304, with pipework in 316-grade steel. All components in direct contact with the material being sprayed and the product are stainless steel or other food quality materials. The design ensures all areas of the machine are fully accessible for cleaning and every effort is made to ensure the hygiene aspects of the machine are to the highest possible standard.
System Electrical Requirements
These machines require a single phase mains power connection for operation, the equipment will be configured to work with the standard single phase voltage systems in the country of operation. Note: If a Temperature Control System is integrated into the unit then a 3 phase supply will be required.
UK Power Requirements: 240V Single Phase 50Hz & Earth