FEATURES OF THE NEW GENERATION OF IPS PRESSING SYSTEMS:

The experience and knowledge gained during the production of IPS pressing systems enabled the engineers and automation specialists to design a significantly modernised and improved construction and introduce many significant improvements to the control system.

• The piston feed speed has been optimised, which results in shorter batch times (the product is held in the press for lesser time)
• Long-term durability of the device has been achieved by precise manufacturing and fitting of the cylinder and piston as well as by using the highest class sealing
• Reliability of the pressing system has been significantly increased by the fact that the parts of the pressing mechanism are made of the highest quality of stainless steel alloys. This facilitates cleanliness and increases the failure-free factor
• High quality filter sheaths and drains with a service life of more than 4,000 hours have been used
• The control system has a dedicated formula for the production of NFC juices with reduced batching time to a minimum
• The new generation of IPS press guarantees a quick service response and maintains a constant stock of spare parts and consumables to minimise the time needed to carry out necessary repairs

"Both the robust construction and the application of the high quality components guarantee the best performance and a maximum yield."

The IPS press is a device controlled by an advanced system. The installed software enables visualisation of processes in the form of clear synoptic diagrams with descriptions and displayed parameters on the monitor screen.

All software for control and visualisation systems are developed by our team of programmers. In this way, we are independent from external companies and can meet the customer's requirements and implement the necessary changes. Programmers are involved in all stages of the project - from the creation of specifications, through the preparation of the electrical diagram, programming the control and visualisation system, preparation of documentation to the start-up of the device.

As a result of continuous development and improvement of both the structure and control systems, a new software version was implemented, which brings many improvements and conveniences for the operator and the person supervising the operation of the entire production line. 

We invite you to read the presentation of the new functions of the hydraulic control system of the IPS press.  

The press is a hydraulic piston-cylinder pressing unit designed for pressing juices. Its robust structure as well as the applied components guarantee maximum efficiency and the highest obtainable yields, and the applied stainless steel structural elements ensure no corrosion.

Batch times start from 70 minutes and depend on the raw material and the extraction cycles carried out. Our service includes operator training and maintenance work. With a centralised spare parts and consumables warehouse, we guarantee uninterrupted and reliable operation.

From the touch panel it is possible to supervise the process in automatic mode and to operate individual components of the device in manual mode.

The basic functions of the system include:

• registration of indications
• presentation of current and historical measurements and process variables
• creation of reports documenting the course of processes
• signalling of alarm conditions with message archives
• management of the system of technological process recipes (if the process is based on the recipes)

Our programmers put special effort on:

• highest quality of workmanship
• transparency of the created systems
• standarization of the created software
• improvement of product quality
• reduction of production costs

NFC juice production dedicatet press: IPS 5.000

Program for extracting NFC juices:

• short time of pulp processing
• optimum pressure
• juice separation depending on the time of the pulp's stay in the chamber and separation by directing the product to separate juice lines: PREMIUM (NFC) / STANDARD (CONCENTRATE)

Design solutions to prevent juice deposits in juice plates.

No loss, closed, highly efficient pressing system with filter drainage elements is  used for solid liquid separation mainly in fruit juice industry. IPS is an ideal solution for juice extraction from apples, berries, black currants, cherries, grapes, stone fruits, pomegranates and vegetables. Everywhere where the highest extraction yield with low suspended solid content and the highest reliability are required IPS 5.000, 10.000 or 15.000 press is the best choice.

The IPS pressing systems are also used for herbal and spice extraction and dewatering sediments from other products. Due to its design and implementation of intelligent control system in the IPS press, it is possible to obtain high quality NFC juices and achieve maximum yield through multiple extraction of pomace as part of a single working cycle. 

Due to its structure and application of an intelligent control system, IPS press enables obtaining high quality NFC juices and achieving maximum yield through multiple extraction of pomace as part of a single working cycle. A reliable structure of the pressing system and application the components supplied by the world's leading manufacturers have made it possible to manufacture presses with one of the highest capacities and yields in the market.

Constant rotation of the cylinder during the pressing and decompression cycles ensures the most favourable loosening of the pressed pulp, which ensures maximum pressing efficiency and easier unloading of the press. This also extends the service life of the cylinder drive.

ADVANTAGES

• Oil level and temperature can be monitored from the operator panel
• Linear transducer inside the main cylinder for pressure plate position measurement, laser measurement of shell position
• Dedicated flow meter for fruit pulp flow measurement
• Stainless steel press covers fitted with electric locks for safe operation
• Availability of service parts and service teams
• Easy access to press operation via freely positionable covers
• Spare sockets for faceplate guides
• The use of juice chambers in the endplate and faceplate with systematic discharge of juice results in maximum yield, optimal pulp loosening, easier unloading and longer life of the cylinder drive (no cylinder stalling during forward movement of the piston)
• Robust and reliable structure, selfoptimising process control system
• Adjustment of main piston speed and pressure as well as jacket cylinder pressure can be done from the touch panel
• Cylinder drive structure allows speed adjustment from operator panel and facilitates soft start and stop
• Local pressure transducers for quick diagnostics of the hydraulic block with display of current pressure values

1.  Pressing unit

Stamping unit Supported by two main pans;
it consists of:
• Shell with three hydraulic cylinders
• Juice collecting endplate
• Faceplate with juice collecting plate and telescopic tube system for juice extraction
• Centrally positioned hydraulic cylinder connected to the faceplate
• Three chrome-plated guide columns to hold the entire structure together
• Drainages in the endplate and faceplate by means of quick fasteners

2. Rotary drive of the discharge

Constant rotation of the cylinder during the discharge and expansion cycle ensures maximum efficiency and increased drive service life:
• Gearmotor with three-phase motor with electromagnetic brake
• Chain transmission
• Plain bearings with central lubrication system

3. Hydraulic power unit

Increased power of the unit on the newgeneration press:
• Hydraulic block with control valves
• Multi-piston variable displacement pump
• Gear pump for cooling and filtering system
• Hydraulic oil filter and cooler
- full flow filter
- oil-air cooler
• Local pressure transducers for quick diagnostics of hydraulic block

4. Control system

Based on an advanced controller designed for automation of machines and production lines:
• PLC Simatic S7-1500 from Siemens
• Control and power cabinet
• Touch panel including WinCC visualisation mounted on the movable arm
• Operation from PC control room through Profinet
• Safety circuits for covers

5. Juice collection system

Fresh juice tank with a capacity of 2,500l, for juice collection and automatic press cleaning:
• Piping for juice tank including fittings
• Measuring instruments: pressure transducer, level transducer, temperature sensor, valve position sensors
• Fresh juice pump
• Electromagnetic flow meter to measure water used for extraction
• Electromagnetic flow meter for measuring the quantity of mash

IPS type press is a horizontal rotary press. This design carries a horizontal hydraulic piston operating within the cylindrical hollow body of the press.

Pressing process begins with pre-filling. Pulp is pumped centrally into the closed cylinder, thus filling the space in the pumping chamber. Filling is carried out with the piston moving backwards. Initial filling of the cylinder is followed by a cyclical filling with initial compression of the pulp.

Depending on the type and quality of a raw material, different portions of pulp are delivered for extrusion until the optimum full load is reached. This is ensured by a selfoptimised control system.

Once the filling cycle is complete, the actual pressing operation takes place. The piston exerts pressure on the pulp and the juice flows out through filtering elements into the two juice chambers built into the faceplate and endplate.

Thanks to the telescopic pipe system, the cylinder does not stop during the piston pressure phase and the juice from the chamber in 

the pressure plate is continuously drained directly into the juice head through which it enters the sanitary juice container.

The piston then retracts with simultaneous rotation of the cylinder so that the entire pulp is thoroughly aerated. This phase is repeated in cycles, with each piston stroke being a few millimetres larger than the previous one, until the preset distance of the piston from the faceplate is reached.

The production process consists of the following sequences: Filling – Pressing – Extraction – Discharge. The final part of the process is the emptying of the pressing system. This is done by opening the sheath with the piston retracted, and the pomace is gravitationally ejected outside.

The closed system guarantees a hygienic process with no juice loss as well as simple and automated cleaning process.