Rockcote fluid bed drying system significantly reduces energy use

System Benefits

  • 25% Production Costs Energy Savings
  • 1200 Bags/Hr Bagging and Palletising
  • 24 TPH Plant Capacity

A leading provider of architectural coatings, Rockcote experienced high demand for their pre-mixed render product, necessitating the construction of a new manufacturing facility capable of producing around 40,000 tonnes of product per year.

Rockcote place high importance on environmentally friendly practices; thus the solution turn-key designed by Brolton Group focussed on energy and resource efficiency. The production process is designed around a gravity feed system, and combined with energy efficient machinery significantly reduces the plant’s energy requirements.

A fluid bed drying and cooling system installed in the plant dries the sand with minimal dust generation. The sand is fed into the dryer utilising gravity fed pneumatic operations, exiting the cooling system and stored for batching. The fluid bed dryer provides Rockcote savings of more than 20% over rotary drum dryers.

The plant has capacity of 24,000 tonnes per hour, with 1200 bags of pre-mixed render bagged and palletised per hour.

Solution Overview

Brolton Group designed and constructed the plant for Rockcote, including complete civil, construction, mechanical and electrical services.

The processing facility incorporated:

  • 9 Bulk materials in-feed system
  • Raw materials processing
  • Fluid bed drying providing 25% savings
  • 8 weighing & dosing of additives
  • 90 sec batch mixes
  • Bagging & palletising 1200 bags/hour
  • Plant capacity of 24 tonnes / hour
Project Brief Rockcote V2 (pdf 2.77 MB)

Case Study Topics: Electrical Engineering Engineering Mechanical Engineering and Fabrication

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