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Mono Muncher reduces bulk tannery waste
applications general processing
Mono Muncher reduces bulk tannery waste Animal by-product regulations and rising disposal costs have led Scottish tannery W J & W Langs to install a Mono Muncher® at its plant in Paisley to reduce bulk waste and improve the efficiency of composting as an alternative to landfill. Each month W J & W Langs tannery, based in Paisley, Scotland, produces approximately 500 tonnes of fleshings – a bulky waste product stripped from the hides prior to tanning. More stringent restrictions on disposal, such as increased landfill tax and higher penalties for incorrect disposal, led the tannery management to look for a better way of dealing with the waste, and so they turned to Mono’s Scottish distributor, Clyde Associated Engineers, who had previously helped this customer to improve their waste handling on site. Mono says that it has researched the technical problems facing waste handlers to determine how progressing cavity pumps and grinders – designed to handle biodegradable waste – can provide effective solutions to help companies involved in animal waste disposal help meet these new stringent restrictions.
WORLD PUMPS April 2005
Disposing of waste Mono discovered that the need for food processors to comply with legislation and reduce waste disposal costs is prompting many processing plants to replace their labour intensive and ineffective waste handling methods, with low maintenance, environmentally friendly alternatives, enabling cost effective waste handling and disposal. Cost reduction across the whole waste handling process, improved hygiene, and the reduction of unpleasant odours when moving waste products across site are also becoming priorities for food manufacturers and processors. Independent research suggested that the majority of food processing plants in the UK currently pay out far more than necessary on waste handling and disposal.
www.worldpumps.com 19
applications general processing ”Simply by installing a macerator to effectively reduce the solids size of various on site waste material, most of the plants we visit could reduce their volume of waste by up to 40%, thereby substantially reducing transport and collection costs,” claims Mono Pumps business development manager, Ian Hallows.“Maceration also improves the homogeneous consistency of biodegradable waste, making it far simpler to recycle, re-use as agricultural fertilizer, or employ as a means for producing methane gas in a digester, which in turn can be utilised as a valuable fuel on site.”
Installing the Series ‘A’ Muncher In 1997 a Mono W Range widethroat pump was installed at the W J & W Langs tannery to pump tannery waste 30 m directly to a waste disposal area, creating a more hygienic and enclosed waste disposal system. Specially designed to efficiently pump material with a high solids content, the W range pump removed the need for manual handling of the fleshings and put to an end the constant 30-minute cycle of filling and forklifting away skips full of the material. In the latest development, a Series ‘A’ Muncher has been installed on the vertical pipeline of the pump discharge to process the waste fleshings. The fleshings are macerated to a small particle size to assist the biological breakdown of the material, and are then collected by a waste management company and composted for use as top soil for extinct landfill sites, or as fertilizer.
“The cost of waste disposal has been substantially reduced by macerating the fleshings and sending them on for composting, but the benefits are more than just monetary,” says tannery engineering manager William Alexander. “The process is far more efficient, easy to maintain, and has resulted in a safer working environment.” The Mono Series ‘A’ Muncher is a twin-shaft, low speed, high torque grinder. Biodegradable waste is fed into the Muncher to pass through a series of cutters, which revolve at differential speeds to pull apart, crop and shear any solids. Liquid passes through the cutter stacks, whilst the solids are trapped and macerated to a small, consistent particle size, to help comply with legislation and improve process efficiency. The Series ‘A’ Muncher is also available for pipeline or channel installation and has a the shaft speed of 85 rpm which offers low cutter tip speeds and can therefore dramatically reduces wear rates in comparison to high speed macerators. In the range, there are six channel models covering capacities of 0-780 m3/h and six pipeline models covering a 0-325 m3/h capacity range. Each shaft is fitted with a series of interleaving cutters and spacers to give real positive displacement solids grinding. The differential speed of the cutter stacks pull apart fibrous material, whilst the leading edge and sides of the cutter teeth crop and shear plastic into small pieces. The circumferential ‘land’ of the cutter crushes friable or brittle material.
Integrated control panel
Animal by-product regulations and rising disposal costs have led a Scottish tannery to install a Mono Muncher at its plant in Paisley.
20
www.worldpumps.com
Each Muncher is supplied with a Programmable Logic Controller (PLC) which can protect the machine against damage from rogue materials and overloads. This can be as an individual PLC unit, a chassis backplate, or a complete control panel. The Muncher PLC is designed to distinguish between a locked rotor full overload requiring instant reversal and a varying allowable periodic low level overload allowing an ongoing running period before the reversal mode is engaged. The critical time/power relationship is continually monitored by the logic to avoid either unnecessary shutdowns or failure to respond to genuine overloads that less sophisticated systems could induce. This logic control unit is programmed to operate in a normal On/Off mode and also to sense an overload condition (jam), momentarily reverse the cutters to clear the condition and then return to normal operation. If a third overload (jam) occurs within 60 seconds of the first, the machine will then automatically shut down in reversed mode and an alarm circuit will be energised.
WORLD PUMPS April 2005
Mono Muncher reduces bulk tannery waste Animal by-product regulations and rising disposal costs have led Scottish tannery W J & W Langs to install a Mono Muncher® at its plant in Paisley to reduce bulk waste and improve the efficiency of composting as an alternative to landfill. Each month W J & W Langs tannery, based in Paisley, Scotland, produces approximately 500 tonnes of fleshings – a bulky waste product stripped from the hides prior to tanning. More stringent restrictions on disposal, such as increased landfill tax and higher penalties for incorrect disposal, led the tannery management to look for a better way of dealing with the waste, and so they turned to Mono’s Scottish distributor, Clyde Associated Engineers, who had previously helped this customer to improve their waste handling on site. Mono says that it has researched the technical problems facing waste handlers to determine how progressing cavity pumps and grinders – designed to handle biodegradable waste – can provide effective solutions to help companies involved in animal waste disposal help meet these new stringent restrictions.
WORLD PUMPS April 2005
Disposing of waste Mono discovered that the need for food processors to comply with legislation and reduce waste disposal costs is prompting many processing plants to replace their labour intensive and ineffective waste handling methods, with low maintenance, environmentally friendly alternatives, enabling cost effective waste handling and disposal. Cost reduction across the whole waste handling process, improved hygiene, and the reduction of unpleasant odours when moving waste products across site are also becoming priorities for food manufacturers and processors. Independent research suggested that the majority of food processing plants in the UK currently pay out far more than necessary on waste handling and disposal.
www.worldpumps.com 19
applications general processing ”Simply by installing a macerator to effectively reduce the solids size of various on site waste material, most of the plants we visit could reduce their volume of waste by up to 40%, thereby substantially reducing transport and collection costs,” claims Mono Pumps business development manager, Ian Hallows.“Maceration also improves the homogeneous consistency of biodegradable waste, making it far simpler to recycle, re-use as agricultural fertilizer, or employ as a means for producing methane gas in a digester, which in turn can be utilised as a valuable fuel on site.”
Installing the Series ‘A’ Muncher In 1997 a Mono W Range widethroat pump was installed at the W J & W Langs tannery to pump tannery waste 30 m directly to a waste disposal area, creating a more hygienic and enclosed waste disposal system. Specially designed to efficiently pump material with a high solids content, the W range pump removed the need for manual handling of the fleshings and put to an end the constant 30-minute cycle of filling and forklifting away skips full of the material. In the latest development, a Series ‘A’ Muncher has been installed on the vertical pipeline of the pump discharge to process the waste fleshings. The fleshings are macerated to a small particle size to assist the biological breakdown of the material, and are then collected by a waste management company and composted for use as top soil for extinct landfill sites, or as fertilizer.
“The cost of waste disposal has been substantially reduced by macerating the fleshings and sending them on for composting, but the benefits are more than just monetary,” says tannery engineering manager William Alexander. “The process is far more efficient, easy to maintain, and has resulted in a safer working environment.” The Mono Series ‘A’ Muncher is a twin-shaft, low speed, high torque grinder. Biodegradable waste is fed into the Muncher to pass through a series of cutters, which revolve at differential speeds to pull apart, crop and shear any solids. Liquid passes through the cutter stacks, whilst the solids are trapped and macerated to a small, consistent particle size, to help comply with legislation and improve process efficiency. The Series ‘A’ Muncher is also available for pipeline or channel installation and has a the shaft speed of 85 rpm which offers low cutter tip speeds and can therefore dramatically reduces wear rates in comparison to high speed macerators. In the range, there are six channel models covering capacities of 0-780 m3/h and six pipeline models covering a 0-325 m3/h capacity range. Each shaft is fitted with a series of interleaving cutters and spacers to give real positive displacement solids grinding. The differential speed of the cutter stacks pull apart fibrous material, whilst the leading edge and sides of the cutter teeth crop and shear plastic into small pieces. The circumferential ‘land’ of the cutter crushes friable or brittle material.
Integrated control panel
Animal by-product regulations and rising disposal costs have led a Scottish tannery to install a Mono Muncher at its plant in Paisley.
20
www.worldpumps.com
Each Muncher is supplied with a Programmable Logic Controller (PLC) which can protect the machine against damage from rogue materials and overloads. This can be as an individual PLC unit, a chassis backplate, or a complete control panel. The Muncher PLC is designed to distinguish between a locked rotor full overload requiring instant reversal and a varying allowable periodic low level overload allowing an ongoing running period before the reversal mode is engaged. The critical time/power relationship is continually monitored by the logic to avoid either unnecessary shutdowns or failure to respond to genuine overloads that less sophisticated systems could induce. This logic control unit is programmed to operate in a normal On/Off mode and also to sense an overload condition (jam), momentarily reverse the cutters to clear the condition and then return to normal operation. If a third overload (jam) occurs within 60 seconds of the first, the machine will then automatically shut down in reversed mode and an alarm circuit will be energised.
WORLD PUMPS April 2005