iPS Technologia

Professionally and safely implement projects meeting the demans of customers and high quality requirements

Selected projects

Experience over 22 years of activity allows us to provide our customers comprehensive solutions that raise the maximum productivity of their businesses.

Many years of experience of our designers allows us to implement effective solutions to companies from other industries for their individual needs.

We invite you to become familiar with our selected realizations. List of implementation is on the left side of the screen and is divided into three gupy:

Food industry


Energy drinks

DESCRIPTION OF INVESTMENT:

Syrup preparation system based on sugar and sweeteners in the Zabierzów plant.

EFFECT:
  • Production of energy drink syrup that supply bottling line with a working capacity of:  cans 250ml – 50 000 cans/ h PET 1000 ml capacity 10 000 items/ h.
  • Technological project of deployment the syrup production equipment has enabled full automation of the production process, connection to other sections
  • Technological optimization of CIP station has enabled the full automation of the washing process and preparation of appropriate cleaning solutions.
  • Achieving high reproducibility of production for the final product.

Cornflakes

DESCRIPTION OF INVESTMENT:

Production line for extrusion products (cereals, corn)

EFFECT:
  • Reaching full capacity line over the first 2 months of production,
  • Achieving the objectives of product quality through the use of extruder Clextral,
  • Using the Y-Tron Disolvera to accelerate the process of dissolving solids in liquids at the station to prepare the syrup maltozowego,
  • Implementation of all the installation process: steam, compressed air, water.

Chocolate mass

DESCRIPTION OF INVESTMENT:

Production line of making chocolate masses. Technological design, realization, installation and commissioning of the system for storage, transporting and dispensing bulk materials for the production line of embossed products. Design, execution or selection of missing equipment in the line from other manufacturers, delivery, installation and commissioning of a production line of chocolate masses for the new plant.

EFFECT:
  • Improved productivity by optimizing product flow production routes in relation to the old system
  • Running the production lines on time, which in the process of making and pre-rolling masses of chocolate produces an intermediate for the production of chocolate
  • Implemented solutions enable supervision over the work of storage devices, unloading and transporting, and monitoring and accountability of raw materials at every stage of production

Hops drying

DESCRIPTION OF INVESTMENT:

Project implementation and installation of lines for processing of hop cones.

EFFECT:
  • The prototype line for the processing of hops was put into operation. This is the only such line in Poland (3rd in Europe)
  • Full automation of the production process from the adoption to the finished product so that the whole plant can be operated by 2 people.
  • The solutions allow to change the production process and the production of granulates with different concentrations of essential oils depending on client needs.
  • Innovative technological process involving fragmentation and separation of the aromatic resin of hops performed at 35 Celsius degrees.
  • Line Capacity 4 tons on one shift.

Starch

DESCRIPTION OF INVESTMENT:

Station purification of raw starch hydrolyzate

EFFECT:
  • Technology for the purification of raw starch hydrolysates fulfil the specification of the investor, the need of cleaning substrates with extremely different filtration properties (from the maltodextrine hydrolyzates to the glucose hydrolyzates, obtaining hydrolyzates from different types of raw materials: potato starch, corn, wheat),
  • Principle of proposed method of purification of raw starch hydrolysates is to combine into integral whole three unit operations and processes:
    • initial preparation of raw hydrolyzate, filtration intensification
    • refining – discoloration and deodorization with active carbon
    • separation of solid impurities by one-or two-step (depending on product type and quality of raw material) pressure filtration with the final control and clearing up filtration

Sugar - warehousing, technological transportation

DESCRIPTION OF INVESTMENT:

Central storage system and dispensing of sugar

EFFECT:
  • Implementation and start-up of designed by our engineers installation of unloading tank, installation of loading and unloading of the silo, transportation of sugar on the production lines. The main process being executed in this part of the production line is grinding granulated sugar in a mill which is supplied to the factory
  • The air used to the transportation of sugar from the tanker to a storage silo is cleaned, dried and chilled, so the product do not gets moisture and caking during storage
  • Silo is equipped with an active bottom to facilitate unloading, as well as the precipitator, Finisher shredding sugar and automatical latch . Under the silo is a storage tank with a metering valve. This ensures the safety of attendants and reliability even while unloading sugar of lower quality
  • Minimization the effects of possible explosions on all tanks by the use of membranes against explosive with decompression channels
  • The monitoring of discharging of static electricity reduces the risk of explosion during unloading. Unloading the tank can begin by connecting to the device. In the absence of grounding automatic valve is closed and prevents unloading
  • The system is equipped with two fans mounted in a special soundproof room. Adequate moisture provides air dryer
  • Magnetic trap mounted on the tank and unloading system to the mill hopper  protects against damage to the installation of machines located in the further process, removal of any ferromagnetic particles from the transported product
  • The process of grinding and transportation takes place automatically. The line of  transportation of powdered sugar is monitored by pressure and temperature sensors
  • Monitoring of pollution filters, dust collectors by pressure sensors provide their high reliability. In the case of pollution the system turn off the transportation and notify the service about the need to purge the filters

Sugar - unloading, technological transportation

DESCRIPTION OF INVESTMENT:

Modernization the installation of unloading and storage of sugar

EFFECT:
  • Modernisation of storage installation and the unloading of sugar crystal. In the existing installation sugar was stored in 50 kg bags and after manual unloading,  by pneumatic transportation, sent to the tank on the production line. After modernization, sugar is delivered by tank trucks, unloaded with pneumatic method to a new storage silo with a capacity of 45 t. Sugar is transported from the silo by pipelines to the new tank on production line
  • Tank truck unloading system is provided with a monitoring system of grounding to ensure dissipation of electrostatic charge that reduces the risk of explosion during unloading
  • Setting the silo on three extensometers, provides inventory control
  • Dust collector installed on the silo reduces the risk of an explosive atmosphere. Explosion-proof membrane system protects against the effects of explosion of the atmosphere by the discharge of the shock wave in a safe area, thereby protecting the entire installation
  • Pressure sensor on precipitator inform  the staff about the degree of contamination of filters and need their cleaning
  • Chopper (Finisher) – eliminates clumping of sugar increasing the efficiency of pneumatic transportation
  • The task of dryer is to create a bag of dry air above the sugar level in a silo to protect it from clumping due to moisture.
  • Magnetic trap installed on the pipe of pneumatic transportation provides stopping ferromagnetic pollutions.
  • Sensors installed in the system can inform about status on every stage of the process. Controling the installation is performed from the surveillance station operator panel. This installation can be started and stopped whenever you want.
  • All processes associated with the unloading, storage and transport are supervised by a central control system and will take place without human intervention.

Salt - technological transportation

DESCRIPTION OF INVESTMENT:

Installation of salt loading and unloading from the mill

EFFECT:
  • The system of pneumatic transportation of salt from a storage silo consists of two separate installations:
    • Installation of pneumatic transport of salt to the fourth floor
    • Installation of salt transport to the mill – a new installation based on an independent fan and dispenser – efficiency 3,5 t / h
  • The piping system of the pneumatic transportation system was modified, two-way splitter was eliminated, the main cause of clogging the pipeline in the previous installation
  • Modification of salt infeed system from the silo to the pneumatic transport systems allows simultaneous loading of salt to two independent pneumatic conveying installations
  • Salt hopper tank is used to assembly of product inventory in order to evenly supply pneumatic transport. The tank is equipped with assistive devices for discharge in the form of a pneumatic hammer and membranes
  • Magnetic separator in the exit from the dispenser protect against entering ferromagnetic impurities to the installation
  • Pulse dust collector eliminates dust around the zone of filling the buffer tank
  • After grinding, the product is loaded with screw conveyor into the Big-bag set on the  weight platform. Sensor system allows full automation of the loading process. To ensure the dust-free filling of BIG-BAG, the screw conveyor is equiped metering valve
  • The bag with the contents is received from the position with a forklift

Analysis of the risks of explosion

DESCRIPTION OF THE INVESTMENT:

The explosion risk assessment of the installation working at the tea faculty, starch, station of big-bag – Everest and pneumatic transport installation.

EFFECT:
  • Inventory of the process installations for the risk assessment
  • Classification of equipment and facility in accordance with ATEX including:
    • explosion risk analysis (for each point of the installation concerned – identification and assess threats)
    • determination of explosion hazard zones (handing installation drawings with marked the explosion hazard zones and the conclusions and recommendations presenting security manner where it is necessary)
  • Perform risk analysis enabled the adaptation of machines and their surroundings to the existing ATEX rules and directives

Siloses explosion protection

DESCRIPTION OF INVESTMENT:

Explosion protection system of silo installation.

EFFECT:
  • Modernisation of the line technology including installation of new storage tanks of stainless steel.
  • Explosion protection system for silo, adapted to current standards
  • Protection against the moving of effects of explosion beyond silo. Isolation of explosion made ​​using a powder system which are cylinders with damping substance actuated by means of optical sensors, which was installed on the inlet pipe to the silo and aspiration piping
  • classification of the equipment and facility in accordance with ATEX including:
  • Analysis of risks of explosion
  • Selection of protective devices against explosion
  • Marking explosion hazard zones
  • Transportation of substances implemented pneumatically
  • Installation of weighing and transport with screw conveyors

Chemical industry


Organic and mineral fertilizers

DESCRIPTION OF INVESTMENT:

Supply, implementation and installation of fertilizer production department. The technological line is composed of nodes: granulation, blending, and packaging of the product. The final product is a mineral-organic or mineral fertilizer – in the form of granular pellets. System efficency – 2 t / h.

EFFECT:
  • Modular design enables the implementation production process by combining the respective transport routes and the implementation of different blends.
  • Production reporting system
  • Security system with the designation of hazardous areas according to ATEX and use of equipment dedicated for them.
  • Minimized the length of road transport through double-deck arranged individual machines of the production process.
  • Prototype Installation

Liquids for cleaning and disinfecting

DESCRIPTION OF INVESTMENT:

Installation of production fluids to clean and disinfect

EFFECT:
  • The final product is liquid Kop, Vanish and Harpic of different compositions. These are liquids used in households for washing, cleaning and disinfection
  • The entire technological process consists of several major phases, from preparation of raw materials dispensed by the dispensing it from containers, mixing, quality control, filling in the bottles and packaging
  • Automation of processes allow 3 people to operate the entire line
  • Production fluid is produced without wastewater, takes place in a closed system. Washings after washing of installation will be managed by re-production of the same type of fluid
  • The operator is controlling the technological process playing the primary role. The whole installation is equipped with the necessary sensors and instrumentation to allow visualization of the processes at each stage of production
  • Buffer tank system allows maximum use of mixers
  • The process uses equipment enabling quality control. The parameters must be compatible with the product data sheets and are subject to quality assurance for the laboratory, so we get a product with identical characteristics and quality

Paints

DESCRIPTION OF INVESTMENT:

Installation of manual administration and dosing of components – installation of the production of ready mixes. Delivery, installation and commissioning of the object

EFFECT:
  • Installation of administration and dosing of colorant is built based on the weight platform
  • Pump system allows for quick pumping of substances between the tanks and the implementation of many recipes
  • Mechanical dosing of 200-liter barrels – barrels are set on mobile dosing systems, mixed on the mixing stations, dispensed into the vat with a diaphragm pump controlled by manual valves. Each mobile dispensing system is designed to support only one type of colorant. This arrangement ensures quick interchangeability of the barrels and production flexibility
  • The installation gives the expandability by adding further elements and extending the range of manufactured products
  • Versatile solution allows processing of small batches (50 liters) and large (up to 1 000 liters)
  • Mobile systems are dispensing carts on which 200l barrel of colorants are set. On the top of barrel there is the cover on which there are mounted:
    • diaphragm pump
    • stirrer
    • turntable completed with three-way valve
    • suction lance
    • vent
    • an additional outlet with manual valve

Adhesive tape

DESCRIPTION OF INVESTMENT:

Installation of preparation and administration of coating materials

EFFECT:
  • Building of high-performance production line of coating materials, based on the three pressureless mixers V = ok.1900l. – Elements having contact with a product made ​​of stainless steel AISI-316. Coil heating – cooling (max.3 bar) placed on the bottom and mantle of tank to 2 / 3 of its height, provides stability in the process. In order to obtain high-quality of product is used special disc mixer.
  • To improve operational safety of filling, mixing and emptying the mixers from the product is carried in shield of nitrogen.
  • Aspiration of filling process the bulk products was carried out using pulse dust collectors secured with explosion-proof membranes. The innovative pulse dust collector system (air dedusting of dust, which can cause clogging and even explosion). Cartridge filter is automatically regenerated (cleaned) from accumulated dust with compressed air pulses fed into the cartridge, which ensures maintenance-free operation for many hours depending on pollination.
  • Administration of fluid substances and solids to the mixers by means of pneumatic diaphragm pumps.
  • Features five pumping systems installed on separate mobile platforms “pump carts” allows full interchangeability between the various phases of the process.
  • Washing of the installation is carried out by administering a detergent to the washing heads of mixers, and farther to the installation meets the applicable standards.
  • Equipment designed for operation in explosion hazardous areas – zone 1

Mineral granules

DESCRIPTION OF INVESTMENT:

Installation of the preparation of granules

EFFECT:
  • Design, construction and commissioning of production lines of granules
  • Multilevel arrangement of process equipment reduced the distance between the individual processes so that the work of the entire system runs in without conflict, both technological and logistical
  • The use in the installation of high quality components of machinery and equipment made ​​it possible to automate and minimize the participation of operators in the production process
  • Properly designing of mechanical part made ​​it possible to equip the installation of the preparation of granules in installation of monitoring and visualization of automation system
  • A recuperator allows for heat recovery from exhaust air outside the building and pre-heating the air blown in the drying system. This solution greatly reduces energy costs in the production process
  • High repeatability of the process makes that we get high-quality product

Related industries


Concrete mass

DESCRIPTION OF INVESTMENT:

Technological line for manufacturing the finished product – special concrete mix to cover the top layer of roof tiles

EFFECT:
  • Implementation the installation in innovative technology Cisar for the production of special concrete mix covering the top layer of tiles. This is the most modern technology of  tiles production
  • Based on the mixer HOSOKAWA the solution for administration and weighing the individual components that meet the highest criteria in terms of reproducibility established procedure, and translates into a finished product durability and minimizes faults in the final phase of the process
  • Dosage of cement from the silo into the reservoir was carried out using the system of two screw conveyors. First conveyor – rough dispensing, second conveyor – exact dispensing. Thanks to this reduced process to a minimum while maintaining high accuracy realized recipes
  • Use in tank system reduces downtime intermediate stages of production to a minimum thanks to parallel realization of the sub-processes that allow continuity in the administration of a mixture to tile production line
  • Ready-mix, depending on the needs is transported by the screw pump to the tile production line
  • The installation is integrated into the existing technological systems so there was no need to make significant changes in other industries.
  • Designed by us technological solutions have enabled us to fully automate the process

Dust extraction in the production of glass wool

DESCRIPTION OF INVESTMENT:

Project Execution and delivery of extraction system components and exhaust gas cleaning and installation of process water in a glass wool factory

EFFECT:
  • We fully implemented extractor system and installation of flue gas cleaning and process water
  • The extraction system and exhaust gas treatment system was installed at 7 nodes producing glass wool. Aspiration system provides exhaustion of polluted process air from these nodes with five high power fans. Air purification is done by the system of cyclones. Such cleared atmosphere meets the purity standards and enables its ejection through the air chimney
  • The system of water sprayers in the installation allow the removal of fine particles glass wool (waste) in the downhill shaft. This improves the quality of the finished product
  • The installation of process water is a closed system. Contaminated water circulate in the system and is being cleaned by a system of sieves and filters. Such purified water can be used repeatedly in the same process. This arrangement provides considerable savings in water and wastewater, and meets all environmental standards for facility
  • While designing structure of platform the crane assembly was included, being used to move fans to maintenance, repair or replacement. This solution significantly reduces the time of review and improves the function associated with it

Transportation of highly explosive materials

DESCRIPTION OF INVESTMENT:

Installation of dispensing of aluminum dust and aluminum and magnesium mixture to existing mixers.

EFFECT:
  • Increased transport efficiency through the use of a new pneumatic system (vacuum transport using a vacuum pump), in the context of productivity increase.
  • The new (manual) system of dispensing particulate aluminum-magnesium (Al-Mg) to the existing Eirich mixer, and to a new Eirich mixer ensures encapsulation of the process (minimizing the hazard zone of explosion)
  • System protection against explosion for the weighting tank (in consultation with companies specializing in the selection of protection systems)
  • Implementation of emergency exhaust ventilation (10 times more air exchange) on the station of filling powders into a pneumatic transport system
  • Exchange of the equipment on an existing line (dispenser systems, weighing system, valve of tank weighing , etc.) resulting in adaptation the existing equipment to explosion hazard zones (minimum zone 22) and protected against a possible outbreak.