Industrial Processes • Assembly and Joining
Industry- economic activity concerned with the
processing of raw materials and manufacture of goods
in factories.
Process- systematic series of actions, steps, or
operations designed to achieve a specific outcome or
goal.
An industrial process refers to a series of activities and
operations that are systematically organized and carried
out within an industrial setting or manufacturing
environment to transform raw materials, components,
or inputs into finished products or intermediate goods.
Key characteristics of industrial processes;
• Standardization
• Repetition
• Automation
• Quality Control
• Safety Protocols
• Environmental Considerations
REPETITIVE MANUFACTURING-This type of industrial
manufacturing process is used when repeating the
production of a product.
JOB SHOP MANUFACTURING-These are made-to-order
items for clients with workstations that are usually
dedicated to one specific product.
DISCRETE MANUFACTURING-This type has a greater
variety than the repetitive manufacturing. Therefore, it
can have more recurrent changeover and variation in the
process.
BATCH PROCESS MANUFACTURING-Driven by customer
demand and the availability of raw materials, this type of
manufacturing is similar to discrete and job shop
processes.
Methods Involved in Industrial Process;
• Machining and Fabrication
• Chemical Processes
• Casting and Moulding
• Heat Treatment
• Extrusion and Forming
Silos;
TOWER SILO
• Tower silos serve as structures for the storage of
bulk agricultural materials, primarily grains and
silage.
LOW OXYGEN TOWER SILOS
• is a type of tower silo that is specifically designed
to store and preserve grains, particularly cereals
like wheat, corn, barley, and oats, in an
environment with reduced oxygen levels.
BUNKER SILOS
• The primary function of a bunker silo is to store
and preserve bulk agricultural materials, most
commonly high-moisture forage crops
BAG SILOS
• Bag silos consist of large plastic bags made of
durable, airtight material that are filled with
chopped forage and sealed to create an
anaerobic environment for fermentation and
preservation.
Types of feeder in manufacturing;
APRON FEEDER
• Apron Feeders are robust feeders used for
handling many types of materials, such as
aggregates, minerals and recycled materials.
• Apron Feeders are used to feed material in a
wide variety of material handling applications,
from mining ores, aggregates, scrap/recycle
material or any special material you have. They
can handle small and large capacities from 10-
6,000 tph and can withstand extreme impact
loading.
BELT FEEDER
• Belt feeders are short belt conveyors that are
specifically designed for material flow
regulation, extracting material from one area
and ensuring that downstream equipment
receives the appropriate volume.
DRAG AND RECLAIM FEEDERS
• Drag Feeders are well suited for moving free-
flowing materials, such as coal, lignite, salt,
copper and other minerals, while Reclaim
Feeders are typically used for moving stockpiled
materials.
VIBRATING GRIZZLY FEEDER
• Vibrating Grizzly Feeders provide the functions
of feeding and scalping. Used in many types of
applications to supply a continuous feed rate,
Vibrating Grizzly Feeders feature a pan section at
the feed end and a grizzly section at the
discharge end that allows undersized material to
bypass the crusher.
WOBBLE FEEDER
• Wobble Feeder offer the dual benefits of feeding
material at a controlled rate and scalping fines
from the feed. Rotating elliptical bars on the
deck of the feeder cause the lumps of material to
move up and down, scrubbing against each other
as they advance toward the discharge end.
Conveyor & Conveying System
A conveyor system is a common piece of mechanical
handling equipment that moves materials from one
location to another. Conveyors are especially useful in
applications involving the transportation of heavy or
bulky materials.
Designing a conveyor system;
• Capacity Requirements
• Length of Travel
• Material Characteristics
• Processing Requirements
• Life Expectancy
• Cost
Main elements of a conveyor;
CONVEYOR DRIVE
• The drive unit controls the speed of the electrical
machine by changing the current and the
frequency.
• Fixed-speed drives maintain a fixed speed and
are suitable for processes that don’t require a
change in speed during the operation.
• Adjustable-speed drives can change the speed
of the motor, during operation. And the speed
can be regulated manually or using an automatic
system.
CONVEYOR MOTOR
• Conveyor Motors for conveyor drives are
generally of 240- and 480-V ratings.
• The squirrel-cage motor is most used with belt
conveyors and with drives up to 7.457 kW (10 hp)
AUXILIARY EQUIPMENT
❖ They are the addition support equipment. For
example,elevating conveyors must be equipped
with some form of holdback or brake to prevent
reversal of travel.
CONTROL OF CONVEYORS
Control has been enhanced considerably with the
introduction of process-control computers and
programmable controllers, which can be used to
maintain rated capacities to close tolerances. This ability
is especially useful if feed to the conveyor tends to be
erratic.
Types of conveyors;
CHUTE CONVEYOR
• Conveyor chutes are used in bulk handling to
perform a variety of operations. In particular, the
loading of a belt conveyor, and the transfer of
material from one moving belt conveyor to
another, are important tasks.
Types of Chute Conveyor:
1.GRAVITY CHUTE CONVEYOR
❑ An unpowered conveyor. Uses the force of
gravity to move materials over a downward path.
2.SPIRAL CHUTE CONVEYOR
❑ Ideal to transfer loads from level to level quickly
and efficiently without interrupting the conveyor
process.
❑ Without extra manual handling or transfers to
other equipment.
WHEEL CONVEYOR
• Wheel Conveyors or Skate Wheel Conveyors and
are an alternative version of non-powered roller
conveyors.
 ROLLER CONVEYOR
• Roller Conveyors use parallel rollers mounted in
frames to convey product. They may be powered
by gravity, a motor or manually.
CHAIN CONVEYOR
• Chain Conveyor uses tightly connected plates as
carriers to transport products along the
production line, which can meet the
transportation requirements of beverage
labeling, filling, cleaning and other equipment
during the transportation process.
There are three types of chain conveyors;
➢ Scraper type chain conveyor
➢ Apron chain conveyor
➢ Bucket chain conveyor
SLAT CONVEYOR
• Slat conveyors use a slat and chain system to
move components along an assembly line. They
are often used where production operations are
performed with the parts located on the
conveyor.
BUCKET CONVEYOR
• Bucket elevators are the simplest and most
dependable units for making vertical lifts.
• They are available in a wide range of capacities
and may operate entirely in the open or be
totally enclosed.
Types of bucket elevators;
CENTRIFUGAL DISCHARGE ELEVATORS
• These elevators are the most common Mounted
on a belt or a chain, the buckets are spaced to
prevent interference in loading or discharging.
This type of elevator will handle almost any free
flowing fine or small-lump material such as grain,
coal, or dry chemicals
POSITIVE DISCHARGE ELEVATORS
• Elevators of this type are essentially the same as
centrifugal-discharge units except that the
buckets are mounted on two strands of chain
and are snubbed back under the head sprocket
to invert them for positive discharge.
CONTINUOUS DISCHARGE ELEVATORS
• These elevators are generally used for
larger-lump materials or for materials too
difficult to handle with centrifugal-discharge
units.
VIBRATING CONVEYOR
• Most vibrating conveyors are essentially
directional-throw units which consist of a
spring- supported horizontal pan vibrated by
a direct connected eccentric arm, rotating
eccentric weights, an electromagnet, or a
pneumatic or hydraulic cylinder.
SCREW CONVEYOR
• Screw conveyors, or auger conveyors, are
industrial equipment used in transporting
bulk quantities of granular solids (e.g.,
powder, grains, granules), semi-solids,
liquids, and even non-flowing materials from
one point to another.
• Screw conveyors primarily consist of a
rotating screw shaft that is installed within a
trough.
PNEUMATIC CONVEYOR
• A Pneumatic Conveyor is a combination of well-
engineered components that work together to
move substances and materials safely,
efficiently, and economically. It is a system that
uses a series of flexible pipes connected to a fan
or blower to move dry, fine materials using
airflow
BELT CONVEYOR
• One of the basic tools in material handling
industry,Belt conveyors are most used in
transportation of bulk materials (grain, salt, coal,
ore, sand, etc.).
Types of belt conveyor;
FLAT BELT -A type of belt conveyor in which the
carrying run of the conveyor belt is supported by
flat belt or by a flat surface. They are suitable for
low speed and low capacity
MAGNETIC BELT -A type of conveyor where
either a magnetic slider bed or magnetic pulley is
used to transport materials.
TROUGHED BELT -Troughed belt conveyor is that
in which the belt forms a trough on the carrying
side while running over the rollers which are
 either in set of 5 rolls, 3 rolls or 2 rolls. They are
suitable for bulk quantity materials.
Maintenance of conveyors
Maintenance, in general, affects all aspects of
operational effectiveness and risks, not just
system availability and cost- specifically safety,
operational efficiency, energy efficiency, product
quality, and environmental integrity
Maintenance of conveyor systems divides into
three broad categories:
➢ Predictive
➢ Preventive
➢ Corrective
Planning to Avoid Emergency Repairs
• Conveyor maintenance can and should be a
straightforward, predictable process — not an
emergency event. However, it can easily turn
into one. The proper design of a conveyor system
assures that power and loads are well balanced
and that stress points are within controlled
limits.
• The forces that occur at start-up and at stops can
be quite surprising
• Proper system design is a must for protection of
the equipment investment, system safety,
system availability, ease-of-maintenance, as well
as the long- term, value-producing capability of
the entire operation.
Predictive Maintenance to Eliminate Surprises
Two basic types of predictive maintenance.
• Replacing components at regularly scheduled
intervals - usually during scheduled shutdowns -
so that total failure of a component is avoided.
• Another to replace components as indicators of
excessive wear or impending failure present
themselves
Preventive Maintenance Extends Component and
System life
• The re-lubrication of components at specified
intervals
• General housekeeping activities
• Alignment of all components and belt splices.
• The removal and replacement of worn or
damaged belt sections
• Tests of electrical components
• Replacement of wear items such as motor
brushes at appropriate intervals.
Corrective Maintenance
• Corrective maintenance, which involves the
replacement of a component after it has
demonstrated signs of imminent failure or has,
in-fact, failed, should be seen as a last resort.
Size reduction of solids
SIZE REDUCTION
Size reduction of solids refers to the process of reducing
the particle size of solid materials through various
mechanical methods. Size reduction is a common
operation in industries such as pharmaceuticals, food
processing, chemical engineering, and mining
Importance of size reduction;
Compressibility- Size reduction can improve the
compressibility of powders, making them suitable for
tablet or pill formation in pharmaceuticals and the
compaction of powdered materials in various industries
Enhanced Mixing and Blending -Smaller particle sizes
facilitate uniform mixing and blending of different
components in a material.
Improved Solubility -Reducing the particle size of certain
materials, such as drugs in pharmaceuticals, can increase
their surface area and enhance their solubility
Easy to transport -Materials that have been grinded or
pulverized allows ease in transportation
Types of size reduction machine;
CRUSHERS-Low-speed machines that are employed for
coarse reduction of large quantities of solids. (150-
250mm)
Types of crushers
JAW CRUSHER -This type of crusher uses a fixed
jaw and a moving jaw to create a V-shaped cavity
through which materials are crushed. It's commonly used
in mining and recycling industries and is known for its
efficiency in primary crushing
GYRATORY CRUSHER- A gyratory crusher is a
type crusher used in mineral processing and ore
processing plants. It operates by means of a gyrating
mantle (a cone-shaped interior surface) and an eccentric
motion (a rotating eccentric shaft) that causes the
mantle to move in a circular pattern within a concave
bowl-like chamber.
ROLLER CRUSHER -Size reduction machine that operates
by compressing the material between two rotating
cylindrical rollers, which are equipped with teeth or
crushing elements that grip and crush the material as it
passes through them
GRINDERS (INTERMEDIATE AND FINE) -redue crushed
feed to powder.
HAMMER MILLS -hammer mills are machines which are
used to shred materials into fine particles or they are
machines used to break and crush pieces of hard,
frangible materials, such as rock and mineral ores, into
smaller pieces
ROLLING-COMRESSION MILL - This mill works on the
principle of compression by applying stress. Stress is
applied by rotating heavy wheels or rollers.
BOWL MILL -Bowl is made to rotate at medium speed for
proper pulverization of coal.
ROLLING MILL - in metalworking, rol l ing is a m etal for
m ing process in which m etal stock is passed through one
or m ore pairs of rol ls to reduce the thickness and to m
ake the thickness uniform
ATTRITION MILL -the attrition mill is a device for m
echanical ly reducing sol id particl e si ze by intense
agitation of a sl urry of m aterial being milled and coarse
millling media.
ULTRA FINE GRINDERS -Mills that reduce solids to such
fine particles are called ultra fine grinders
COMPARISON OF CRUSHER AND GRINDER
CRUSHER MACHINES
• By compression
• Large into small lumps
• Dry feed only
• Heavy duty and slow speed
GRINDER MACHINES
• By impact and attrition
• Powderized product
• Either dry or wet feed
• Light duty and high speed
CLASSIFYING HAMMER MILLS
BALL MILLS -Mechanical device used to crush
material in powdered form. The Grinding medium is balls
that is made of stainless steels, steel, ceramic or rubber.
FLUID ENERGY MILL -Size reduction unit results
from attrition between rapidly moving particles of the
material being ground.
AGITATED MILL -Agitated media mills stir the
grinding media to break down the target material into
ultra-fine particles
Separation & Classification of Solids
Solids -Solids have a definite shape and volume. The
particles in a solid are closely packed (making it
incompressible) and have limited motion. Examples of
solids include rocks, metals, and wood.
Classification of Solids
1. Amorphous Solids -The term ‘amorphous’ ,
when broken down into its Greek roots, can be
roughly translated to “without form”. Many
polymers are amorphous solids. Other examples
of such solids include glass, gels, and
nanostructured materials.
2. Crystalline Solids -Solids containing constituent
particles of matter organised and arranged in a
specific manner are crystalline solids.
Ways to SeparateSolids;
1. Handpickin- This method involves simply picking
out all the unwanted substances by hand and
separating them from useful ones. The
separated substances may be an impurity that
has to be thrown away or maybe that both the
separated substances are useful.
2. Threshing -This method is mostly done during
the harvesting of crops. Normally, the stalks of
the wheat are dried once it is harvested. The
grain is then separated from the stalks and
grounded into the floor by beating the dry stalks
to shake off the dried grains
3. Winnowing -When the grains are collected from
the process of threshing, it needs to be cleared
out of husks and chaffs before it is turned into
flour. Normally the separation of the mixture is
carried out with the help of wind or blowing air.
4. Sieving -This method is mostly done during the
harvesting of crops. Normally, the stalks of the
wheat are dried once it is harvested. The grain is
then separated from the stalks and grounded
 into the floor by beating the dry stalks to shake product quality and safety. Proper separation and
off the dried grains classification processes help companies comply with
5. Magnetic Separation -When one substance in these regulations, avoiding fines and legal issues.
the mixture has some magnetic properties then
this method is quite useful. Strong magnets are
commonly used to separate magnetic elements.
6. Evaporation -Evaporation is a technique that is
used in separating a mixture, usually a solution
of a solvent and a soluble solid. In this method,
the solution is heated until the organic solvent
evaporates where it turns into a gas and mostly
leaves behind the solid residue
7. Sublimation -is the separation technique where
a substance makes a transition from the solid to
the gas state directly.
8. Filtration -The most common method of
separating a liquid from an insoluble solid is the
filtration
Importance of Separating Solids;
1.QualityControl -Manufacturing industries often deal
with raw materials or components in solid form.
Separation and classification processes help ensure that
these materials meet the required quality standards.
2.Product Uniformity -Achieving uniformity in product
characteristics is crucial in manufacturing. Separation
and classification methods are used to segregate
materials based on size, density, or other attributes,
ensuring that the final product meets precise
specifications
3.Process Efficiency -Proper separation and
classification can significantly enhance the efficiency of
manufacturing processes.
4.Resource Optimization -Separation and classification
processes can help manufacturers make the most of
their resources. By segregating materials effectively,
companies can minimize waste and reduce raw material
costs.
5.Safety -In industries where hazardous or toxic solids
are involved, separation processes can be crucial for
removing harmful substances from the final product,
ensuring the safety of both workers and consumers.
6. Environmental Impact -Effective separation and
classification can lead to reduced environmental impact.
Industries can minimize waste generation, control
emissions, and recycle materials more efficiently,
contributing to sustainability goals
7.Compliance withRegulations -Many manufacturing
industries are subject to strict regulations regarding