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SERVICES





We develop products that will bring substantial customer benefits.








MANUFACTURING




SHAFTS AND HUBS

Shafts are manufactured to a stringent straightness tolerance of 1mm/metre of shaft length. Often 50% of this is achieved.

Ears are attached to circular hubs using deep penetrating continuous welds. Ears are never attached directly to hollow shafts.

Hubs and ears are machined using CNC machines to minimise clearances between ear and hub. This ensures weld strength.





IMPELLER BLADES

AFX manufactures impellers for all applications, including high viscosity duty. However, as most applications are either flow or shear dependant, the F3 range of high flow impellers, or the P4 range of high efficiency gas dispensers, are the workhorses of the AFX stable. Other impellers available are flat blade radials, pitch blade turbines, high viscosity anchors and helicals, and specialised impellers for pumping, foam breaking and dispersion. Impellers can be manufactured in all materials, including exotics, and can be coated in rubber, urethane, epoxy or other specialised materials. Impeller blades are carefully checked to ensure that tolerances on angle, camber and curve are maintained. Out-of-specification blades are rejected. Blades are machined where hub and ear attach to ensure flatness. Often, the problem of loose blades are caused by blade flexing, resulting from a lack of flatness. Where rubber and urethane lining is required, the leading edges of the blade are machined to maximise bonding with the metal blade.





BEARING PEDESTALS

The incorporation of robust pedestals are critical for the reliable operation of some large agitators. These independent units are designed to accommodate all the loads and forces applied as a result of the mixing action. This ensures that the gearboxes are only required to tolerate the torque imposed, and are isolated from the thrust and bending moments. Pedestals are carefully machined to ensure accurate alignment with the gearboxes. The upper and lower mounting surfaces are machined (the entire unit is machined on a 5-axis machining centre to ensure accuracy with the bearing bases and mounting surfaces).





MOUNTING BASES

Mounting bases are critical components in ensuring that the gearboxes are correctly aligned and mounted to the beams or structure. This reduces the potential of twisting or flexing of the gearbox housing - a common cause of failure of proprietary gearboxes. All large, top entry AMX Agitators are fitted with integral mounting bases, or pedestals where necessary. All bases have machined pads, or surfaces, top and bottom, to ensure accurate and positive alignment.





Pumps

PUMPS

AFX PUMPS are at the forefront of peristaltic pumping technology. Developed to handle near impossible pumping applications, the AFX series pumps have become industry favourites.

AFX pumps consist of the housing, hose and drive unit. The casings are supplied in a standard powder coated mild steel, which are mounted on a fabricated support structure for secure placement. The AFX pump is supplied complete with the drive unit (gearbox and motor)hose suited to your application as well as the first oil fill. This enables the client to carry out the installation and commence operating within minutes. The AFX PUMP SERIES are manufactured within a set of standard casing sizes for supply, however each pump is configured to suit the process application requirements. The AFX PUMP SERIES are assembled and undergo a stringent quality check before being released from our head office workshop for delivery.


ENGINEERING




DESIGN

To eliminate potential design errors, AFX ensures that all its manufacturing drawings are produced in 3D.  A process known as Finite Element Analysis (FEA) is used in instances where large, or infrequent components are designed.  The analysis combines all the operating loads of the system, allowing the designer to see potential flaws before manufacturing takes place.





FINITE ELEMENT ANALYSIS

AFX makes use of Finite Element Analysis (FEA) for its designs allowing its engineers to model the combination of loads applied to the actual components resulting from the impeller’s rotation system, and its interaction with fluids and slurries.  By making use of this method, the applied bending moment, torque and thrust can be predicted and adequately accommodated in the design.  Detailed FEA is required in instances where important components carry critical loading.  Shown below are some examples of our FEA applications.





CFD TECHNOLOGY

Computational Fluid Dynamics (CFD) is the method of applied mathematics, physics and computational software used to visualise how a gas or liquid flows, as well as how a gas or liquid affects certain objects as it flows past. AFX makes use of CFD in numerous applications to calibrate flow numbers, view velocity vectors and assist with solving process problems.



AUDITS





MIXER AUDITS

We have a high-level of expertise in mixing processes and mechanical design that can provide innovative solutions from fresh angles. No matter the make or type of mixer, our systematic approach from our highly experienced engineers can determine if improvements can be made in your plant. Mixer studies range from basic audits and plant surveys, to complete troubleshooting programs. Working in close association with your plant personnel, data is collected and processed in our simulation package to pin point any weaknesses in the existing design. We will provide you with a detailed report of our findings with any future recommendations.

Optimising plant operations can considerably increase your profits. It is not unusual for payback times to be measured in just weeks or months. Any improvement in product recovery or quality, with minimum capital outlay, results in additional revenue that directly increases profit.


The following situations are examples of where our audits have led to identifiable improvements:

  • Newly-commissioned plants
  • Plants that have experienced gradual changes and an evolution of the process scheme, addition of new equipment and/or personnel changes.
  • Plants that have been in operation for many years and want to investigate new or improved technologies.
  • Plants that would like to increase their production and mitigate risk.
  • Analysis of new tanks or agitation processes, especially if a client would like to develop new mixing techniques.

PUMP AUDITS

As specialists in the field of Peristaltic Hose Pumps, we have a high-level of expertise that can often highlight simple yet highly cost effective changes. No matter the make or type of the Peristaltic Hose Pump, our systematic approach from our highly experienced engineers can determine if improvements can be made to your system. Pump studies range from basic audits and system surveys, to complete troubleshooting programs. Working in close association with your plant personnel, data is collected and processed through our own bespoke in house design and pump sizing package to pin point any shortfalls in the existing system and pump setup. We will provide you with a detailed report of our findings with any future recommendations.

Optimising even small parts of the plant can often considerably increase profits. It is not unusual for payback times from our recommendations to be measured in just months. Any reduction in operational and maintenance costs or process improvements can result in additional revenue that directly increases profit.


The following situations are examples of where our audits have led to identifiable improvements:

  1. Newly-commissioned plants where pumps have been incorrectly installed.
  2. Plants that have experienced gradual changes and an evolution of the process scheme, with the addition of new equipment and/or personnel changes.
  3. Plants that have been in operation for many years and want to investigate new or improved technologies.
  4. Analysis of alternative problematical solids handling pumps where clients wish to consider alternative pumps to reduce whole life costs.

SERVICE AGREEMENTS




Based at the new Afromix facility in 25a Rudo Nell Road, Jet Park, Johannesburg our new service team is staffed by highly qualified and experienced engineers. All work is completed to ISO 9001:2008 accreditation, and is CE certified.

Service provided by AFX will provide the most cost-effective solution with regards to the price of spare parts and labour against the cost of a new equipment. 


REPAIR AND REFURBISHMENT

AFX offers a comprehensive repair and refurbishment service for your mixing and pumping equipment, including an on-site hose replacement service for both our own and 3rd party peristaltic hose pumps.

Quality is assured with all repairs being completed with original, or where unavailable, high quality remanufactured parts. The AFX group also manufactures its own range of mixing and pumping equipment, so is able to offer cost-effective replacements of old or obsolete equipment that is beyond economic repair.


PREVENTATIVE AND CONTRACT MAINTENANCE PROGRAMMES

AFX can recommend a maintenance scheme to suit your individual needs

  • Minimise down time or lost production
  • Extend mean time between overhauls
  • Assist budget planning by being aware of the condition of current equipment
  • Maintain your process efficiency

AFX can provide regular inspections on most installations and can tailor the service to meet your needs giving your plant a longer working life and help increase your return on investment.

The AFX service team operates worldwide and can provide a wide range of servicing either within our own service centre or on site at client premises.


DIAGNOSTIC, PERFORMANCE AND HYDROSTATIC TESTING AND INSPECTION

At our Jet Park service centre we have the facility for calibrated testing of new and repaired mixing and pumping equipment.


SITE SURVEYS

Site surveys can be conducted to ensure you have the correct mixing or pumping solution in the short, medium and long-term.

  • Audit of your site systems
  • Specification of new or replacement equipment to be installed
  • A stock and stores review to identify critical spares
  • An assessment of stock levels to be held on-site or in a bonded stock area

DESIGN, INSTALLATION AND COMMISSIONING OF MIXING AND PUMP SYSTEMS

The AFX team can supply and install your complete mixing and pumping systems...

  • Turnkey package systems
  • Innovative Chemical Dosing Systems 
  • Mechanical and electrical installation of complete systems to include mixers, tanks, pumps, pipe work and control equipment
  • Electrical wiring to include certification where required
  • Certified drawings
  • Commissioning of your mixing and pumping system and control philosophy ensuring the correct application and that the specified duty of the installed package satisfies all of its requirements.

We can also work to design, specify and retro-fit enhanced mixer and pump solutions into an existing system.

TECHNICAL SOLUTIONS




Through our team of highly experienced field service engineers and technicians we are able to offer clients a range of training options to suit their specific needs. Whether you are looking to provide personnel with basic operation training, product maintenance training or a complex understanding of the equipment and associated process design we can help.


We can provide:

  • A 'hands-on' approach to training so that delegates 'learn by doing'
  • Convenient delivery of training at your own site or in our own facility
  • Customised courses can be created to match specific training needs
  • Comprehensive supporting notes are provided for all personnel