MC 3/60 R mixed-flow dryer

The context

In 2024, a medium-large Italian agricultural company processes between 2,500 and 3,000 tons of corn annually, primarily for use in animal feed. The processed corn is highly valued in the feed industry due to its superior quality. For over 30 years, the company has used a mobile Mecmar S40/310 T2 dryer to handle these quantities and now aims to expand its operations to manage larger volumes while maintaining high-quality standards.

The 30-year-old investment has proven fruitful, enabling the company to grow and add facilities over the years, including a new warehouse, a cooling silo, and a grain cleaning system. With the goal of further increasing production, the company has embarked on a significant modernization program for its drying line to consider future expansions.

In the summer of 2024, the first Mecmar MC 3/60 R dryer was installed, equipped with automatic, high-efficiency energy solutions, including heat recovery and thermal insulation with insulating panels.

Customer needs

The client’s expectations were clear. They needed a drying system that:

• Maintained high production rates
• Was energy-efficient
• Had a low environmental impact regarding dust and noise
• Was equipped with digital and Industry 4.0 technologies to maximize productivity and facilitate remote monitoring

These requirements were essential not only for planning a long-term investment but also to access specific incentives.

Before the installation of the new solution

The client was using a mobile S40/310 T2 dryer with four electric motors and a direct flame heat generator with a diesel burner. While this was a traditional and reliable drying system, it presented some limitations in managing workflow and energy efficiency. The batch operation required personnel to always be on hand to load and unload the dryer quickly to minimize non-productive time.

To increase dryer output, the client added a cooling silo with an elevator. This setup allowed the grain to be heated in the dryer only, while the cooling phase was completed externally.

Subsequently, an unloading auger transferred the dried and cooled grain from the silo to storage. While functional, this system required additional handling steps, which slowed down production and required more labor to maintain efficient operations.

Here is how the drying system was configured:

1. S40 mobile dryer
2. Unloading auger to cooling silo
3. Elevator
4. Unloading auger to storage

Mecmar’s solution: the MC 3/60 R dryer

In the summer of 2024, after evaluating various options, both continuous and batch, the company chose the Mecmar MC 3/60 R mixed-flow dryer.

This advanced solution combines Mecmar’s traditional reliability with cutting-edge solutions:

• Capacity and flow. The MC series continuous cycle dryers are designed to handle large quantities of product in a continuous production process. Corn is loaded at the top of the drying column, gradually descending as it is dried by hot air and then cooled by cold air before exiting.
• Process control. The dryer is controlled by a modern PLC with an advanced architecture that continuously monitors production parameters, ensuring safe operation in both automatic and manual modes and providing precise drying process control.
• Energy efficiency. The dryer features a heat recovery system and is externally coated with thermal insulation panels to retain heat, minimize atmospheric dispersion, and focus maximum energy on drying the grain. The airflow is also optimized for the most homogeneous drying possible, recovering warm air that isn’t saturated with moisture and thus enhancing drying power.
• Environmental impact minimization. High-performance axial fans were selected for this dryer, designed to ensure high airflow with minimal energy consumption. They are equipped with silencers to reduce noise emissions and an anti-dust damper to minimize dust emissions.

Here is the current configuration of the drying system:

1. Loading pit
2. Loading auger
3. Vibrating screen cleaner
4. Auger to elevator
5. Elevator
6. MC 3/60 R dryer
7. Dryer discharge auger
8. Dry grain cleaner
9. Elevator
10. Storage silo
11. Warehouse

After the installation of the MC dryer

With the introduction of the Mecmar MC 3/60 R dryer, the company has significantly improved the efficiency of its drying process.

The new setup begins with a loading pit that feeds a loading auger connected to a vibrating screen cleaner, ensuring the removal of impurities and dust before drying. An auger then transports the product to an elevator, which directs it to the MC dryer.

The workflow is now:

• More streamlined and automated
• Less dusty than before
• Less noisy than before
• Uses less fuel and electricity than before

The dried and cooled product is discharged from the dryer, passing through a dry grain cleaner via a discharge auger, further enhancing grain quality. The elevator then transports the product to storage silos or, if necessary, to the warehouse.

The main advantage of this new system is greater automation and reduced processing times. Additionally, implementing the vibrating screen cleaner and the dry grain cleaner has significantly improved the quality of the final product. The optimized air management and energy efficiency of the MC dryer, with its insulated structure, have reduced energy consumption and environmental impact, especially in terms of noise and dust.

Thanks to the solution provided by Mecmar, the company has been able to continue expanding and improving the quality and efficiency of its drying process, providing high-level service to its customers while meeting increasingly stringent environmental standards.

The facility is now set up to increase production, handle larger volumes, and store more grain.