TSE SPECIFICATIONS.docx
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- Attached to
- Replace Twin Screw Extruder
- Solicitation number
- 1124526SOL
About this file
This document is a technical specification for replacing a twin screw extruder (TSE) at the Phoenix Rearing Facility (PRF), a 69,000 square foot facility that produces 1.5 million insects per day. The TSE is essential for the production of navel orangeworm diet.
The key requirements include: removing the existing TSE and peripheral equipment, providing a new TSE capable of producing 200-450 kg of diet per hour, designing and installing a mezzanine/catwalk, installing the new TSE and performing testing, and training facility staff. The new TSE must meet detailed technical specifications. This is a federal contract opportunity solicited by the Department of Agriculture's Animal and Plant Health Inspection Service. The award will be made to the best value response based on price, past performance, technical capability, and quality control.
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| File | Type | Posted |
|---|---|---|
| Sol_12639524Q0247 TB SI.pdf |
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General Information
| 1.0 | Statement of Purpose: |
| Replacement of twin screw extruder for production of navel orangeworm diet. |
2.0 Background:
The Phoenix Rearing Facility (PRF) is a 69,000 square foot facility that produces and ships approximately 1.5 million insects per day and has the capability to produce more on a as needed basis. Producing these insects in the required quantities and quality and on schedule, requires that diet be prepared according to PRF protocol in the required quantities. The twin screw extruder (TSE) is essential to the navel orangeworm diet preparation process.
PRF is located at 3645 E. Chipman Road, Phoenix, AZ 85040.
Contractor Requirements
3.0 Schedule
| CLIN | Description | Unit | Quantity | Price |
| 001 | Removal of existing TSE and peripheral equipment as described in 3.1.1 | 1 | Ea | |
| 002 | Production and delivery of TSE and peripheral equipment as described in 3.1.2; includes cost of delivery to facility | 1 | Ea | |
| 003 | Design and installation of mezzanine/catwalk as described in 3.1.3 | 1 | Ea | |
| 004 | Installation of new TSE and peripheral equipment as described in 3.1.4 and provision of documentation and training as described in 3.3 | 1 | Ea |
3.1 Technical Requirements/Tasks
The Contractor will remove the existing TSE and peripheral equipment and devices, dispose of all materials, and install the new TSE and peripheral equipment and devices. The tasks outlined below described the work but do not describe all possible tasks. A site visit will be required prior to submitting a quote.
3.1.1 Removal
| • | Contractor will remove the existing twin screw extruder, an APV Baker model MP80/35, from its current location in the diet preparation area and place the new extruder and its feeders and supply tanks and hoppers in the 12”x20” area from which the old one was removed. |
| • | Contractor will remove all old peripheral equipment (feeders, mezzanine, controllers, and metering devices) surrounding the existing TSE. |
| • | The existing TSE is located in a room directly accessible to the outside, no transit through hallways will be required. |
| • | Contractor will removal and dispose of existing TSE and all peripheral equipment in accordance with federal, state, and local laws and regulations. |
3.1.2 Specifications of New TSE
| • | Contractor must provide a new TSE. Not refurbished or rebuilt. |
| • | TSE must be capable of producing 200 to 450 Kg of finished navel orangeworm diet per hour. |
| • | The TSE must be a Coperian ZSK-76Mv Plus or equivalent. Should the contractor propose a TSE that is not the Coperian ZSK-76Mv Plus, specifications of the proposed model must be submitted with the quote and must meet the following minimum requirements: |
| 1. | Gearbox: |
Gearbox maximum torque per output shaft 2730 Nm Maximum torque (Md) per screw shaft 2275 Nm Maximum motor speed 1904 RPM
| Gearbox ratio 3.174 | ||
| Maximum screw speed 600 RPM | ||
| Maximum allowable horsepower at Output Shaft (NVT) 383 HP | ||
| 2. | General Process Section: | |
| 9-barrel sections | ||
| Length of each barrel section (4 L/D) 270 mm | ||
| Length of processing section (L) 2430 mm | ||
| Shaft centerline distance 58.5 mm | ||
| Diameter of screws (ds) 74.60mm |
Flight depth 16.6 mm
| 3. | Motor Data: | |
| Main drive motor 480V, 3Ph, 60Hz , 1800 RPM, 150 HP | ||
| Lube oil pump 240/480V, 3PH, 60Hz, 1750RPM, 2HP | ||
| Cooling Unit 480V, 3Ph, 60Hz, 1750 RPM, 5 HP | ||
| Side Screw 240/480V, 3PH, 60Hz, 1800 RPM, 10 HP |
Vacuum Unit 480V, 3Ph, 60Hz, 1800 RPM 15 HP
| 4. | Process Specification: | |
| 1 feed barrel | ||
| 7 closed barrels | ||
| 1 vent barrel | ||
| • | One Gravimetric solid materials feeder that processes/delivers at least 200 kilos per hour of flour-like diet ingredients. | |
| o | Power supply: 230 VAC, 60 Hz, 1 ph | |
| o | Hi efficiency belt drive | |
| o | Extension hopper constructed of high-grade stainless steel with electropolished material contact surfaces | |
| • | Two feeders capable of delivering 0.25 – 10 Kg per hour of solid materials the consistency of flour/sugar/wheatgerm. | |
| o | Power supply 230VAC, 60Hz, 1ph | |
| o | Twin screw feeder | |
| o | Hopper: 12 Liter (0.4 cubic foot) hopper welded to feeder bowl, constructed of high grade stainless steel with electropolished material contact surfaces | |
| • | Requires 3 loss-in-weight liquid feeders capable of injecting/delivering 10-200 kilos per hour of liquid the consistency of water or corn oil each with a 30-gallon tank with inlet and vent, shut off valve, cleanout port, support legs, drain valve and discharge support. The skid supporting each feeder must be made of stainless steel. | |
| • | We require one injector capable of accurately injecting/delivering smaller quantities (1 to 10 kilos per hour) of liquid such as corn oil or dilute acetic acid with a 2-gallon tank with inlet and vent, shut off valve, cleanout port, support legs, drain valve and discharge support. The skid supporting the feeder must be made of stainless steel. | |
| • | Feeders must be controlled by devices that are adjustable for the full range of output delivery and meter the feed rates. | |
| • | All new equipment must be compatible with and connect to the existing power supply and temperature control supply. Available connections are as follows: | |
| o | Incoming 480-volt 3 phase to main disconnect | |
| o | Incoming 240-volt power | |
| o | Both chilled water for cooling and steam for heating are readily available through 1.5” pipe with standard plumbing connections. |
3.1.3 Design and Installation of Catwalk
| • | Contractor must design and install a mezzanine/catwalk to support the screw conveyor and to access the gravimetric feeders. The mezzanine will have a working floor space of at least 48” x 48” and will be designed to fit the extruder and the large solid materials feeder. |
| • | The structure must be designed and installed according to IBC 2012, ASCE7 design load requirements, AISC and applicable standards. |
| • | The contractor will consult with the COR on all aspects of the design and build. |
3.1.4 TSE Installation
| • | Contractor will install and connect the TSE and peripheral devices (feeders, controllers, and meters). |
| • | Contractor will install the mezzanine/catwalk to support the screw conveyor and access the gravimetric feeders. |
| • | Contractor will perform all required performance testing. Performance will not be considered complete until the twin screw extruder is fully functional and meets the criteria as set forth in Section 3.1.2 above. |
| • | Contractor will report to the COR daily with progress updates or deficiencies noted. No changes to performance, deadlines, or other aspects of the contract can be approved at the facility. |
3.1.4 Training
• Contractor will be responsible for training facility staff on the newly installed TSE until program staff can successfully operate the instrument independently.
3.1.5 Other Requirements
• Contractor will provide all required tools, personnel, and equipment to complete the work described in this document. Contractor is responsible for removing all leftover materials and debris from performance of this contract in accordance with all Federal, state, and local statutes and regulations. No resources will be provided by USDA other than approved electrical and plumbing connections.
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