The PreMix is a 4-in-1 solid matter feeder by Vogelsang

The universal 4-in-1 solid matter feeder

  • Mashes a wide variety of biomass to a homogeneous organic suspension
  • Separates out heavy material and shreds the solids before the pump unit
  • Compact dimensions and easy to link in so its integration is uncomplicated
  • Easy to feed several digesters with just one PreMix
  • Easy and quick service on site


Design and function of the solid matter feeder PreMix
The 4-in-1 unit that separates, mashes, prepares and pumps

PreMix combines four steps within a compact, space-saving unit. The universal feeder system is a combination of our progressive cavity pump (CC series) with the RotaCut RCX cutter. Optionally the solid matter feeder can be equipped with the Debris Removal System (DRS) and Debris Lift Unit (DLU). The biomass is introduced into the side of the system through any feed screw. At the same time, liquid (recirculated material, liquid manure) is added. In a single step, the PreMix turns this into a homogeneous organic suspension and pumps it into the digester. As the biomass is mashed into a homogeneous suspension which can be pumped, multiple digesters can be fed via a pipe network with one PreMix, and additional containers can easily be connected at a later time.

PreMix: Four steps in one unit

  1. Contrary to many comparable feeder systems, the PreMix separates out heavy material from the input while still upstream of the integrated pump unit, which the Debris Removal System then removes during ongoing operation.
  2. The PreMix mixes solid and pasty input materials with liquid into a homogeneous suspension.
  3. At the same time, coarse particles and fibrous matter are cutted.
  4. This means that a well-prepared suspension, free of coarse disruptive matter and foreign matter flows into the pump. This protects the pumping parts and significantly increases the service life of the pump unit.

Service and maintenance of the PreMix solid matter feeder
Easy and quick service on site

During the development of the PreMix solid matter feeder, attention was paid to ease of service and maintenance. All necessary work including the replacement of parts subject to wear can be done quickly and easily on site. This keeps interruptions to operation to a minimum.

The innovative pivoting mechanism of the CC series allows maintenance and parts to be replaced on the PreMix pump unit without the need to dismantle parts of the pipes, as is often the case with progressive cavity pumps. The entire stator-rotor unit is simply pivoted upwards or to the side – depending on the local circumstances. The space required and the time for service work is reduced significantly. The cutter is easily accessible due to its generously dimensioned service flap. The cutting blades and cutting screen can be changed in a few simple steps. The proven Quality Cartridge is used to seal the drive shaft. This saves time during a sealing change, avoids installation errors and improves safety.

Digitalize your product!
Control technology for Vogelsang technology

Investing in our progressive and smart control technology significantly boosts the performance and efficiency of Vogelsang machines and systems. It captures and continuously monitors key parameters like the capacity or throughput rate, rpm, pressure and power consumption. The control detects malfunctions early, and rectifies them by intervening appropriately. The integrated communication interfaces like ProfiNet and OPC UA can exchange data with other systems or a superordinate control in real time.

At the same time, the web-based user interface displays all key data clearly in all major browsers. Optionally, the data can be accessed on mobile devices for remote monitoring.

Our experts’ experience from hundreds of applications in various areas constantly inspires our software development and lays the foundation for the major benefits for the users: low operating costs, maximum availability and efficiency.

Our range of controls offers the right solution for all machine requirements and all customers’ needs. From ready-to-use, factory-tested and commissioned system solutions for end users, to basic versions for experts who want to put the finishing touches to the control technology themselves.

Options in control technology for the PreMix

Features of the PreMix

The PreMix is distinguished by its unique concept: In a PreMix heavy material is separated out and material with long fibers is cut before entering the pump unit. This enables even difficult and demanding input materials to be reliably prepared, protecting the pump unit and significantly extending the service life.
The unique arrangement of the components and the direct connection between the RotaCut and the suction housing of the pump unit creates an extremely compact feeding system which is easy to integrate, even when retrofitting on existing plants. For four steps, you only need a few square meters, which includes space for service and maintenance.
Both for the progressive cavity pump in the CC series as well as for the RotaCut in the RCX series, all of the necessary service and maintenance work is easy to do on site, without having to disassemble the lines going to and from the units or any parts of the PreMix.
The housing parts are made of steel. The torsionally stiff design is the basis for the intensive preparation of the biomass in the smallest space. Hot dip galvanization protects the parts of the housing from corrosion.
Both the RotaCut RCX cutter as well as the progressive cavity pump in the CC series are driven by a sturdy helical shaft mounting geared motor with a high operating factor. This is mounted directly onto the drive shaft so an additional coupling is not needed.
A generously sized cardan shaft with two cardan joints ensures reliable transmission of the drive power in the CC series from the parallel shaft geared motor to the rotor. A sturdy sleeve – which doesn’t even have to be disassembled when changing the rotor – protects the shaft against solid and fibrous matter and against foreign matter in the medium.

Additional information:
Readjusting the blades in the RotaCut RCX with the ACCplus ensures that there is permanent, direct contact between the blades and the screen. It is only this contact which makes it possible to reliably chop down materials with long fibers. In addition to this, the ACCplus monitors the state of the blades online, shows it on an external display and in the control system during normal operation.

Options of the PreMix

The Debris Removal System (DRS) removes the separated heavy material during ongoing operation with no need to switch off or open the solid matter feeder or foreign matter separator. The system removes the heavy material with only minimal loss of medium (only around 15 l). In comparison to conventional solutions, the DRS reduces the work required by up to 80%.

Additional information:
The progressive cavity pump used in the CC series is optionally available with a two-stage geometry. This increases the permissible differential pressure, halving the pressure difference per stage, resulting in a longer service life, even with strongly abrasive media and/or high pressures.
On request, the Performance Control Unit (PCU) is available in a variant with a PROFINet connection.
The optional wide screen touch display offers an overview of all of the important information and settings, even outside of the central control. Built into the control cabinet door, all important details are easy to access and set via the intuitive menu.
Optionally, Vogelsang can also offer control hardware and software including the sensors from just one source.
All PCUs are equipped for access via remote maintenance. If access is activated and made possible, operators benefit from uncomplicated software updates and, when events call for it, we can quickly and easily support the customer.

The series of the PreMix

  • The compact, versatile one[br]PreMix / RCX-58G
  • The high performance one[br]PreMix / RCX-68G

The compact and versatile solid matter feeder
Solid matter feeder PreMix / RCX-58G

The compact, standard model for variable solid matter feeding into typical biogas plants. When you need to feed a wide variety of biomass such as organic waste, dry chicken manure, grass silage, and food waste into the digester, this model is the right choice.

The high performance solid matter feeder
Solid matter feeder PreMix / RCX-68G

The PreMix based on the RCX-68G guarantees optimum preparation and feeding of a wide variety of solid matter and substrates with maximum performance and effectiveness. This makes it particularly well suited for large biogas plants and everywhere where intensive preparation of the substrate or high material flow rates are required.

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