Our Rotoform system has long been the industry
benchmark against which all other solidification
systems are judged.
ipco.com---------ROTOFORM-----PASTILLATION------------FOR-------PREMIUM-------------PRODUCTS-------

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-----A SUCCESS STORYBUILT ON PERFORMANCE,RELIABILITY AND IPCOSERVICE

From its introduction in the late 1970s right up to the present day,our Rotoform system has set the standard against which othersolidification systems are judged.

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Rotoform
installation inclean room.

Its groundbreaking performance – delivering anend product of consistent shape and size
– has seen the process adopted as thesolidification solution of choice for hundreds ofproducts across the chemical and food industries.

We continue to develop and enhance theprocess, introducing new models – like our
4th generation RF 4G – that enable customers
to gain further market advantage throughimproved product quality and productivity.

The required properties of a granule will varyfrom one product to another of course, but ingeneral terms, successful processing will deliver
granules that are:• Consistently sized (diameters from0.8–36 mm).
• Free-flowing.
• Dry.
• Dust free.
• Easy to dispense.

Choose to work with IPCO and you can be
sure of receiving the support you need to gain
maximum return on your investment, whether
you’re a small family business or an internationalgroup. Our worldwide service and spare parts
operation means we’re there when you needus, the investment we make in initiatives suchas our Productivity Center means we can support
you on product and process development.

The IPCO Rotoform system delivers on all counts.
More than 2 000 have been installed to date,
and this has given us unparalleled expertise indifferent product types, flow conditions, and themany other parameters of this process.

Choose to work with IPCO and you can be
sure of receiving the support you need togain maximum return on your investment,
whether you’re a small family business oran international group.

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Quality, versatility and reproducability– The Rotoform principle

The IPCO Rotoform system delivers pastilles of highly uniform
shape, stability and quality – properties that can be reproduced
again and again – in an environmentally friendly manner.
This ensures that all pastilles are of uniform size,
from one edge of the belt to the other.

The system also offers a high degree ofversatility, enabling products of different
viscosities to be processed or pastilles ofdifferent sizes to be produced simply byexchanging the rotary shell and nozzle bar.
How the Rotoform system works
A pump delivers the molten product from avessel or pit to the Rotoform system via heatedpipes and a filter.
The Rotoform itself consists of a heatedcylindrical stator – which is supplied with liquid
product – and a perforated rotating shell thatturns concentrically around the stator. Dropsof the product are deposited by the nozzle
bar across the whole operating width of acontinuously running stainless steel belt.

The rotation speed of the Rotoform issynchronized with the speed of the belt to allow
a gentle deposition of the liquid droplets onto
the moving belt. Heat released during coolingand solidification is transferred via the steel belt
to cooling water sprayed underneath.
This water is collected in tanks and returned to
the water recooling system; at no stage does itcome into contact with the product.
After the drop has been deposited onto thesteel belt, some product residuals could remain
to the outer shell. A heated refeed bar forces
this product back into the Rotoform and keeps
the outer shell clean.

A system of baffles and internal nozzles built
into the stator provides uniform pressure acrossthe whole belt width, providing an even flow
through all holes of the perforated rotary shell.

Hot Melt Pastillation SystemRotoform
Exhaust air

Steel belt cooler
Supply air

Raw material

Reactor 1

Reactor 2

M

Granules silo

Cooling water
Chiller

Bagging/weighing
Palletizing

Prefilter
Product pump4

Water collecting tankStorageHot melt solidification
plants around theworld are based on IPCO
Rotoform technology.

Key benefits of Rotoform based pastillation• Pastilles solidified directly from the melt,eliminating the energy and equipment
costs associated with subsequent crushing,breaking or grinding processes.
• Pastilles are of a highly uniform shape andstability– dust-free production.
• Pastilles are free flowing and ideal for
handling, blending, storage and furtherprocessing.
• Higher bulk density and better packing
properties than bulky flakes.

• Environmentally friendly production ascooling media (water) and product are kept
apart – no possibility of crosscontamination.
• Fast cooling on the belt means very
few vapor vapor or gas can get into theatmosphere and minimizes oxygen contactof the hot product.
• Melts with widely varying properties can behandled including viscosities from 10 to
40 000 mPas and temperatures up to 300 °C.
• Pastilles can be produced with diametersfrom 0.8–36 mm.

Rotoform process
Sliding pad
Rotating shell
Product channel
Heating channel
Metering
distribution bar
Refeedbar

Sealing

Pastilles
Steel belt

5One basic principle, a model for everyapplication

The Rotoform technology has been developed over many years
to meet the different process requirements of a wide range ofdifferent products.
Building on the principle that has been behind
the Rotoform’s success for more than three
decades – efficient and continuous pastillation
by means of a Rotoform drop depositor and asteel belt for cooling – we now have systems
suitable for the production of pastilles from awide range of chemical melts and food products.
The development of this comprehensive productrange has led not only to faster and more
efficient pastillation, but has also opened up
new opportunities for chemical processing.
Some products have an extremely high melt
tempe-rature of up to 300 °C. Some arecharacterized by their abrasive, sedimenting
or corrosive properties. Others fall into thecategory of subcooling melts.
Whatever challenge you need to overcome,whatever your production requirements are, wehave the Rotoform system to match.

Rotoform 4G – the foundation of a modular
system design
The RF 4G is the latest model to form thefoundation of the Rotoform family. Its namecomes from the fact that this is now the 4thgeneration Rotoform, and it is the result of theexpertise gained through the development,manufacture, installation and commissioningof every previous system.
This is an extremely versatile model, one
capable of solidifying low and high viscous
melts (up to 40 000 mPas) at temperatures up to300 °C, and is widely used for products such as
hot melt adhesives, resins and waxes.
It is also the basis for a modular systems
design, one on which we have built a series of
specialized systems for particular applications –the Rotoform family.

We have systems suitable for theproduction of pastilles from virtually
any chemical melt and a wide rangeof food products.

6Premium solidification with Rotoform system.
IPCO’s Rotoform feed device.

Rotoform Family

Rotoform 4G

Temperature°C (max)Viscosity
mPas (max)Pastille size
mm (max)

Capacityt/h (max)

Typical products

RF 4G

Basic model – standard unit forsolidifying low and high viscous melts

250

40 000404Hot melt adhesives, resins,wax

RF 4G HTFor melts which feed in at hightemperature (up to 300 °C)

300

40 000404Bitumen, high temperatureresin, PET, pitch

RF 4GFD Meets the special requirements ofthe food industry in terms of hygiene
and ease of dismantling/cleaning

200

40 000402.5Chocolate, cheese, chewing
gum base, emulsifier, fat,soup concentrate

RF 4G ASFor abrasive & sedimenting products

250

40 000405Catalyst, stearate,sulphur bentonite, othersuspensions

RF 4G SCFor pastillation of subcooling melts insupercooling plants

200

20 000152Agrochemicals,
photochemicals, plasticadditives, rubber chemicals,
stabilizer

RF 4G CR

For corrosive products

250

40 00040

2.5

Calcium chloride,magnesium chloride

RF 4G MCFor production of micropastilles
down to 0.8 mm diameter

250

1 000

20.5

Additives, UV stabilizer,
waxes

Rotoform S8RF S8Special Rotoform design for therequirements of the pastillation ofsulphur

125–145  103–5

5.5

Sulphur

Rotoform
High Speed

RF HSSpecially designed for high speed,high capacity pastillation of lower
viscose products

180

  100

3–5

11.5

Sulphur, urea, caprolactam

Rotoform MIRF MI

For laboratory, R&D and small
capacity production (<20 kg/h)

200

5 000

120.02

Laboratory use, small scaleproductionRotoformHighPerformance

RF HP

Specially designed for increased
homogenity250

40 000404

Chocolate, resin, hot melt

7Rotoform HS (High Speed) – high capacity
processing

The Rotoform HS (High Speed) granulator builds on the same basic
principle as the standard 4G models but features a much larger
rotating shell that enables significantly higher capacity and speed.
This high performance Rotoform system is ideal
for products with a short cooling time and low
viscosity, like sulphur, Bisphenol A, caprolactam,
MA (Maleic Anhydride) and naphthalene, as
well as a wide range of fertilizer products
including urea.
The main difference between the Rotoform HS
and the base model Rotoform 4G is the muchlarger diameter of the rotating outer shell that
actually deposits the molten product onto thesteel belt.
This means the influence of centrifugal force on
the drop shape is reduced. the system can beoperated at a higher speed while maintaining
control of end product quality – still deliveringa consistent pastille with a regular,
hemispherical shape.

8The engineering that goes into producing adropforming device with much bigger diameterand 30 000+ accurately positioned holes isimpressive enough.
The Rotoform HS is suitable for use withlow and medium viscosity, fast cooling (<20Seconds) products. As product cooling times
are unaffected by the process itself, a systemrunning at twice the speed needs twice thecooling length (up to 120 meters/minute).
Typical capacity of a 1 500 mm wide unit
will be:Sulphur

11.5 t/h

Urea

5.0 t/hCaprolactam

4.0 t/hRotoform HP (High Performance) –reliable, high performance processing

The Rotoform HP (High Performance) rotarydepositing system is built on the proven strengthsof our Rotoform 4G while providing particular
benefits to the challenges of processing of highviscosity products at higher volumes.

This is particularly beneficial in terms of higher
capacity processing of high viscosity products
such as chocolate, but the inherent flexibility ofthis system means it will handle other viscousmaterials with optimal efficiency.

The key difference between the Rotoform HP
and our standard 4G model is a significantly
larger product distribution channel coupled withan increased outer shell diameter. This enables
increased efficiency in terms of even andconsistent distribution of the melt across the full
width of the steel belt cooler, ensuring precise
pastille uniformity.

Other improvements incorporated into thedevelopment of this next generation Rotoform
model include innovative and patented
fea-tures to influence the product distribution
during production. It allows the optimizationof the system to achieve maximum possible
pastille uniformity.
Reliable, versatile and easy to use, theRotoform HP is available on new systems or as areplacement of existing drop forming systems.

Rotoform HP producing chocolate.

9Rotoform MI (Mini) unit for laboratory useDelivering all the benefits of our standard
Rotoform system but on a very small scale, theRotoform MI (Mini) is ideally suited to use inlaboratory testing operations to define quality,
production rates and other key parameters of
products in the development stage.
System capacity depends on the products
being processed and can be up to 20 kg/h.
Maximum melt temperature is 200 °C andproducts with viscosities from 10–5 000 mPas
can be handled successfully.

The Rotoform MI granulation system is basedon a small scale steel belt cooler and matching
Rotoform feeding device, consisting of a stator,
metering bar, rotating shell, refeed bar andthe drive.
The melt is brought via compressed air or inert
gas to the Rotoform MI system where a needle
valve guarantees exact dosing onto the belt. As
with all Rotoform systems, the feed and steel
belt cooler are perfectly synchronized. Coolingis carried out by means of cold water sprayedonto the underside of the steel belt.

The key advantages of this system are:
• Maximum system versatility.
• Premium quality Rotoformpastilles.
• Simple operation and accurate system control.

Typical Rotoform MI PlantProductMelting kettle

Control valve

Rotoform MISteel belt cooler

Compressed airProductdischargeMM
Cooling water
Cooling water return

Rotoform MI installation used with a filled wax.

10Different products from A–Z

Since the introduction of the first Rotoform
system and the development of the full productrange, it has been possible to pastillise manydifferent chemical products, from bulky mass
products such as sulphur or fertilizer, all theAdditives
Alkane sulphonate
Antioxidants
Antiozonants
Anthracene
Asphalt
Bisphenol A
Bis-hydroxyethylterephthalate (BH ET)
BitumenCalcium nitrate
Calcium stearate
Caprolactam
Carbazol
Catalysts
Cobalt naphtenate
Cobalt stearate
Crotonic acid
Detergents
Diaminodiphenyl­
methane (DMA)
Emulsifier
Fat chemicals• Fatty acid• Fatty alcohol• Fatty amide• Fatty ester• Fatty stearate

Food products• Cacao mass
• Cheese• Chocolate• Edible fats
• Gelatine• Gum base
• Sauces• Soup concentrates
Fungicides
Herbicides
Hot melt adhesives• Based on ethylene
vinylacetate,poly­urethane,polyamide,
polyester
Reactive hot melt
Insecticides
Lactam 12
Magnesium chloride
Magnesium nitrateMaleic anhydride
Master batch
Naphthalene
Neopentylglycol(NPG)
Nickel catalyst

way through to fine chemicals such as thoseused in the cosmetic and pharmaceuticalindustries, plus a wide range of plastic andfood products.

Paradichlorbenzol
Pesticides
Photo gelatine
Phthalic acid
Polyethylene glycol
Polyvinylacetate
Powder paints
PVC additive
PVC stabilizers
Resins• Acrylic• Colophonium• Epoxy• Hydrocarbon• Phenolic• Polyamide• Polyester• Silicon• Tall oil
Rubber chemicals
Sodium sulphide
Sorbitol
Stabilizers
Stearic acid
Subcooling melts
SulphurSulphur + Bentonite
Surfactants

Synthetic soap
Tar pitch
TensidesToluene-diisocyanate(TDI)
Triazole (BTA, TTA)
Trimellitic anhydride(TMA)
Triphenyl phosphate(TPP)
Urea
UV-stabilizers
Waxes• Paraffin• AKD• Microcrystalline• PE-wax• PP-wax• Bee-wax• Filled wax• Flavored wax• Wax colors• Montan wax• Coating wax
Zinc stearate11

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