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Automation and mechanization in tea production

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With a yearly consumption of 7.54kg of tea per person, Turkey is the first consumer (per capita/year) of tea around the world followed by Morocco(4.74kg/capita/year) and the United Kingdom ( 3.75kg/capita/year).

A big part of the local consumption is covered by the national production. Indeed, at the collapse of the Ottoman empire Mustafa Kemal Ataturk started a strategical plan to increase the production of tea. He aimed to reduce the importation of coffee and build a strong sector for future exportations. This switch in the consummation habits and production strategy succeeded as Turkey is now the 5th tea producer with more than 6% of the worldwide tea production.

Growing in the mounts of the black sea region, the tea trees are perfectly matching with the regular rains and high rate of humidity characteristic of the region. Covering most of the hills the leaves are harvested in the beginning of summer. There starts a season that will last 3 months. In this busy period, the production is non-stop and the machines are under heavy pressure and workload. We provide gearboxes and electrical motors to the complete production process. Our IRK, IR, IRS series are used to transport, steam, cut, sort, dry and pack the precious tea leaves. Depending on the leaves and type of tea produced, the transformation process is composed of 5 steps.

Steaming: The leaves are washed and treated with high pressured water steam. This step contributes to the fixation of the aroma and specific taste of the tea.

Oxidation: The leaves are “burnt” to activate the color and flavor proper to black tea. This step also reduces the natural acidity of the tea leaves.

Rolling : The steamed leaves are being cut in roller cutting presses, this operation give the final shape of the tea.

Drying : The tea is dried in screening ovens that separate the tea leaves in different categories and removes the small wood and structures.

Packaging : The freshly produced tea is packed and stocked in big paper bags, these are dispatched to distribution and packing centers around the country.

This progress contributed to the development of natural teas growing without any usage of fertilizers of chemicals

As a recent trend major producers and small cooperatives are using mechanization and automation systems to reduce the usage of fertilizer. Indeed, the producers used to grow tea leaves with chemical fertilizers to reach a faster maturity and standards size. Nowadays the mechanization of the production process is helping them to adapt the timing and parameters to each type of leaves. This progress contributed to the development of natural teas growing without any usage of fertilizers of chemicals. Showing how mechanization and automation can help producer to reduce their impact on the environment and considerably improve the quality of their products.

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

Gearbox

Industrial type heavy duty gearboxes by Dişsan

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DA series helical and DK series bevel-helical gearboxes are suitable for heavy duty industrial applications. They are designed to transmit high output torques in optimized dimensions. They enable wide range of ratios with single to quadruple reduction options.

Thanks to their rigid structure, they are suitable to operate safely even in harshest conditions. Housing material is GGG40 cast iron. Gears are produced from high quality, case hardened steel. Heat treatment process is applied to obtain 58-60 HRC surface hardness. The gears are precision ground to ensure a quiet and low vibration operation. 

The gearboxes are available with hollow shaft or solid shaft. According to operating conditions, they are offered with optional accessories such as cooling systems, forced lubrication systems or oil expansion tanks. Back-stops, shrink discs and IEC B5 motor flanges are also available as optional accessorries. Special oil seal options are applied for dusty operation conditions.

Dişsan also offers complete solutions with motor, input coupling, gearbox and output coupling set on a steel base frame. 

For extruder applications, special extruder type right or left output options are available.

Input Options: 

  • Motor adapter for standard IEC B5 motors
  • Solid input shaft, without motor (right input, left input or double input shafts)

Output Options: 

  • Hollow output shaft
  • Solid output shaft (single or double)
  • Output flange

Applications:

Conveyors, Elevators, Mills, Cranes, Washing Units, Mixing Units, Extruders

Industries:

Mining, Construction, Metal Processing, Cement, Concrete Plants, Sand and Gravel Plants, Ceramics and Glass, Plastics

Industrial Gear Unit Types

DA – Helical Gear Units

DK – Bevel – Helical Gear Units

DAE – Extruder Gearboxes

Gearboxes with Auxiliary Drive

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Gearbox

Optimal solutions for the crane and hoist industries

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Active actor of the gearbox market for more than 47 years, I-MAK gearbox continue to propose new and innovative solution to their customers and partners. With more than 1.000.000 product references I-MAK is serving various industries around the world. 

Designed for the hoist and crane industries, the IRC Series have a lifting capacity ranging from 0,5 tons to 50 tons by using various fall combinations. Being based on ISO, DIN and FEM Standards all the calculations and configurations of the IRC Series are matching top class standards to guarantee a maximum of security within a smooth and efficient operation. Available in 5 different size of housings the IRC Series are composed of GG25 for the housing material and 16MnCr5 for the full range of gear. These different parameters allow I-MAK products to provide high quality, high strength, low wear, and silent operation.

Reaching up to 50 tons of lifting capacity the IRC series are taking a key place in the crane and hoist industry around the world with a compact design, easy mounting, and easy maintenance characteristics.

Working in outside or complex environments, under the aggressions of dust, heat, chemicals and water, our gearboxes are protected with a specific C Class painting, dust proof seals and IP 65 to prevent corrosion and any external aggression, which gives our geared motors solutions and increase lifetime and lowering the maintenance costs for the end users. 

IRC gearboxes can be coupled with a large range of input options keeping a smooth operation and long lifetime. The specific design of the IRC Series with long bearing distance and tapered roller are increasing the radial loads capacity matching the requirements of ISO/FEM classifications.

Solutions for the crane and hoist industries of I-MAK are not limited to the IRC Series, as the brand is also providing various other solutions for multiple applications. Parallel geared motors (YP series), helical geared motors (IR Series) and bevel geared motors (IRK Series) are coupled with frequency inverter to provide high precision in translation movement. 

Last year, I-MAK added a new solution for heavy hoist and crane. With 7 new sizes of housing the new M Series is key addition to the existing range of products. Designed with a monobloc housing and various gears configurations, this new line can reach up to 35.500 Nm of output torque in standard configuration, allowing crane producers to reach a lifting capacity of 50 tons. 

The IRC Series and I-MAK solutions are already active in more than 40 countries, serving various industries and multiple applications. Installed in giant phosphates mines of Morocco, the gearboxes are resisting to dust and sun in remoted areas. They are also lifting tons of material in giant steel and foundry plants all over India. Specific and complex configurations are also running all over the US serving various industries. 

In these complicate days and complex actuality, I-MAK continue to keep its core principles and missions. Serving and assisting various industries around the world, with quick and effective answers via a wide network of sales offices, service centres and online engineering support. The brand is also looking into the future with a strong R&D team and partnership with various producers and technological centres around the world. More than ever I-MAK remain an integrated player in the international market of gearboxes and power transmission.

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Reducer

DM Series helical gear reducers from Dişsan

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DM series, monoblock helical gearmotors are available with foot or flange mounted designs.  Upon request, they can be manufactured with motor adapters for standard IEC motors with B5 flanges. The standard motors are in compliance with IEC standarts with IE2 or IE3 efficiency class. DM series gearboxes are produced in nine different sizes and offer easy mounting and flexible connection options.

Thanks to their rigid structure, they are suitable to operate safely even in harshest conditions. Housing material is GG20 or GGG40 cast iron. Gears are produced from high quality, case hardened steel. Heat treatment process is applied to obtain 58-60 HRC surface hardness. The gears are precision ground to ensure a quiet and low vibration operation. 

Input Options: 

  • Direct motor connection
  • Motor adapter for standard IEC B5 motors
  • Solid input shaft, without motor

Output Options: 

  • Solid output shaft
  • Agitator flange

Applications: Conveyors, Spiral Conveyors, Elevators, Cranes, Concrete Mixers, Washing Units, Concrete Recycling Systems, Mixing Units, Agitators, Aerators.

Industries: Mining, Construction, Metal Processing, Cement, Concrete Plants, Sand and Gravel Plants, Chemical and Pharmaceutical Plants, Ceramics and Glass, Water and Wastewater Treatment.

DM Series Gearbox Types:

DMA – Foot mounted, with motor

DMF – Flange mounted, with motor

DNA – Foot mounted, with IEC B5 Motor adapter, without motor

DMFK – Flange mounted, with motor, with agitator flange

DTA – Foot mounted, with input shaft, without motor

DTFK3 – Flange mounted, with input shaft, with agitator flange, without motor

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