Industries

Batching systems for quartz, silica, manganese, chrome ore, charcoal, lignite etc.; 100 Kg to 1000Kg; 20 to 35 batches per Hour.

Furnace Control using both Current method and Impedance method with accurate material batching including burden calculation.

Auxiliary systems monitoring and control

Abrasives

We provide complete Refractory Manufacturing plants on Build-Operate-Transfer basis (BOT) with guaranteed change over times and throughput. These are silo-less – yet fully automated batching plants that allow fast changeover without contamination and very high plant output at low capex investments. Roof heights and plant area constraints are not an issue.

We also provide complete automation solutions to modernize or expand existing manufacturing facilities.

These plants can handle 30-40 raw materials, with various grain sizes of alumina, quartz, felspar, zirconia etc; 300 kgs to 3000 kgs; 1,000 Kgs / Hr to 30,000 Kgs / Hr.

Our plants meet international standards, both in terms of plant environment as well as output product quality.

After working with the industry for over 2 decades, and having done large projects for industry leaders such as Vesuvius, we are leading a revolution in this sector with guaranteed performance metrics on Mixer OEE, throughput, quality and accuracy.

Our unique capabilities in Refractory sector

• Silo-less batching plants & Tap hole clay plants
• Fast changeover between products in <20 minutes
• Reducing cross contamination across products
• High throughput automatic batching
• OEE achievement of mixer up to 95%
• High throughput bagging machines 25/50/500/1000 Kg
• Complete automation despite limitations on floor space and roof height
• Customized and turnkey solutions for different budgets from USD 2 Million to 20 Million
• 7 Types of Plant design schemes.

For a detailed white paper on “Refractory Plant Design” with 7 types of design schemes: please write to rsr@koremec.net / vjk@koremec.net

Batching and weighing of Silica, zirconia etc with various grit sizes and color; Combination of large volume and small volume materials; 100 Kgs to 300 Kgs ; 30 to 40 batches per hour ; 20 gms to 50 gms tolerance.

Storage and batching of 30 to 40 materials can be handled within a small plant area.

Silos, Barrel mixers and Press distribution systems.

Brake shoe

Dispensing of various oils, chemicals and various types of rubber with bar code and RFID interfaces.

Semi Automatic Batching with Bar code, RFID and mixer interface, with storage and retrieval using horizontal and vertical carousel.

Large number of raw materials (80 to 120) can be batched in a small but controlled environment to ensure FIFO, Poke-Yoke, traceability, accuracy and consistency.

Pharma

Mobile Trolley Batching; Collection of material stored in Jumbo bags; Mobile trolley based weighing and feeding with integrated dust collection.

Mono-rail Weighing; Dynamic weighing of material while it is moving on monorail ; Controlled dispensing as per feed rate set.

Mobile Trolley Batching; Collection of material stored in Jumbo bags; Mobile trolley based weighing and feeding with integrated dust collection.

Mono-rail Weighing; Dynamic weighing of material while it is moving on monorail; Controlled dispensing as per feed rate set.

Formulation systems; Reactors, kettles and storage tanks are weighed and fed with materials accurately, as per predefined recipes.

Process control inside reactors and kettles for temperature, stirrer RPM, pressure and time.

Weighing under very adverse conditions like vibration due to agitations, High tare weight and very low material weight, steam / hot water jacketing.

Formulation systems; Reactors, kettles and storage tanks are weighed and fed with materials accurately, as per predefined recipes.

Process control inside reactors and kettles for temperature, stirrer RPM, pressure and time.

Weighing under very adverse conditions like vibration due to agitations, High tare weight and very low material weight, steam / hot water jacketing.

Liquid Batching ; Weighing, material handling and instrumentation.

Raw material unloading, filling, storing in silos, pre-blending/mixing/grinding, batching, addition of molasses, hammer mill optimization, palletisation and Packing.

Electrical Panels, Mechanical equipment, Control systems and Instrumentation.

Power and Control Panels as per IS and IEC standards.

We have extensive experience in control and instrumentation projects related to Infrastructure, Water and Waste-water.

• Reservoir monitoring and control
• Canal automation
• Lift and piped irrigation
• Industrial water pumping & transmission
• Water treatment & distribution
• Effluent treatment
• Sewage pumping & treatment

The technical expertise includes

Instruments	Control	Telemetry	IT
Flow, Level, Pressure, Analyzers (Flow up to 1600 mm dia)	Motors, Valves, Actuators, VFD Drives, MCC & Control Panels, PLCs Dual Redundant systems	GPRS-2G-3G, RF-Radio, VSAT, Fibre, Remote networking of PLCs (300+ locations)	Web/Cloud, SCADA, Servers, Networks, Large and Matrix Displays

Experience with OIL and GAS Industry

One of the large projects executed by us, is for an Oil and Gas MNC. The scope includes
complete Design, Engineering, Documentation, Supply, Installation and Commissioning of
the Instrumentation package for their ETP project inside their refinery complex. The project
complies with ATEX and CCOE standards.

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If you are from an industry not listed here, we suggest you still explore the applications and processes we have handled in the listed industries. You are sure to find parallels with your own industry.

Ferro Alloys

Batching systems for quartz, silica, manganese, chrome ore, charcoal, lignite etc.; 100 Kg to 1000Kg; 20 to 35 batches per Hour.

Furnace Control using both Current method and Impedance method with accurate material batching including burden calculation.

Auxiliary systems monitoring and control

Refractories

Batching and weighing system for various grain sizes of alumina, quartz, felspar, zirconia etc; 300 kgs to 3000 kgs; 1,000 Kgs / Hr to 30,000 Kgs / Hr.

Storage and batching of 30 to 40 materials can be handled within a small plant area.

Vibro sieves, Storage silos, Structurals, Mixers, Bagging and Stitching Machines.

Mobile Trolley Batching; Collection of material stored in Jumbo bags; Mobile trolley based weighing and feeding with integrated dust collection.

Abrasives

Batching and weighing of Silica, zirconia etc with various grit sizes and color; Combination of large volume and small volume materials; 100 Kgs to 300 Kgs ; 30 to 40 batches per hour ; 20 gms to 50 gms tolerance.

Storage and batching of 30 to 40 materials can be handled within a small plant area.

Silos, Barrel mixers and Press distribution systems.

Rubber

Dispensing of various oils, chemicals and various types of rubber with bar code and RFID interfaces.

Brake shoe

Semi Automatic Batching with Bar code, RFID and mixer interface, with storage and retrieval using horizontal and vertical carousel.

Large number of raw materials (80 to 120) can be batched in a small but controlled environment to ensure FIFO, Poke-Yoke, traceability, accuracy and consistency.

Food

Mobile Trolley Batching; Collection of material stored in Jumbo bags; Mobile trolley based weighing and feeding with integrated dust collection.

Mono-rail Weighing; Dynamic weighing of material while it is moving on monorail ; Controlled dispensing as per feed rate set.

Pharma

Mobile Trolley Batching; Collection of material stored in Jumbo bags; Mobile trolley based weighing and feeding with integrated dust collection.

Mono-rail Weighing; Dynamic weighing of material while it is moving on monorail; Controlled dispensing as per feed rate set.

Formulation systems; Reactors, kettles and storage tanks are weighed and fed with materials accurately, as per predefined recipes.

Process control inside reactors and kettles for temperature, stirrer RPM, pressure and time.

Weighing under very adverse conditions like vibration due to agitations, High tare weight and very low material weight, steam / hot water jacketing.

Pesticides

Formulation systems; Reactors, kettles and storage tanks are weighed and fed with materials accurately, as per predefined recipes.

Process control inside reactors and kettles for temperature, stirrer RPM, pressure and time.

Weighing under very adverse conditions like vibration due to agitations, High tare weight and very low material weight, steam / hot water jacketing.

Ceramics & Insulators

Liquid Batching ; Weighing, material handling and instrumentation.

Animal / Poultry Feed

Raw material unloading, filling, storing in silos, pre-blending/mixing/grinding, batching, addition of molasses, hammer mill optimization, palletisation and Packing.

Electrical Panels, Mechanical equipment, Control systems and Instrumentation.

Power (Sub station)

Power and Control Panels as per IS and IEC standards.