RedUnit: Never again downtime in sugar production
Case study: Pfeifer & Langen, Germany
Problem
Increasing volumes of sugar beet tops caused frequent blockages and unplanned downtime in the washing line.
Solution
Two RedUnit industrial grinders ensure reliable beet top shredding and continuous 24/7 sugar production through a compact, redundant design.
The customer and the problem
Founded in 1870, Pfeifer & Langen is one of Europe's leading sugar producers. At its Euskirchen plant in Germany, around 11,000 tonnes of sugar beets are processed every day during the annual beet campaign. Since harvested sugar beets have a limited shelf life, uninterrupted operation is essential.
As Christof Ruhrmann, Head of Production, Primary Production at Pfeifer & Langen, explains:
“Technological sugar production cannot tolerate any interruptions, as the raw material has a limited shelf life. That is why beet processing runs around the clock.”
During primary processing, sugar beets are washed and cleaned while leaves and beet tops are separated for further processing. In recent years, longer growing seasons and changing cultivation methods have led to significantly larger volumes of beet tops entering the washing line. The existing flail chopper could no longer reliably handle these quantities, resulting in weekly blockages, costly downtime, and increased maintenance.
The solution
Following positive experience with RedUnit industrial grinders at another Pfeifer & Langen production site, the Euskirchen plant selected two RedUnit XRL150-500QD twin-shaft grinders.
Installed directly below the washing line discharge chute, the compact grinders eliminated the need for additional conveyor belts while integrating seamlessly into the existing process. Their redundant design ensures continuous operation even if one unit requires maintenance.
Since commissioning in October 2025, the RedUnit has ensured reliable beet top processing with virtually no unplanned downtime. During the entire 2025/2026 campaign, only one blockage occurred when a large branch entered the system. Thanks to the large maintenance hatches, the obstruction was removed within approximately 15 minutes. Compared with the previous shredding technology, the RedUnit also delivers higher throughput while consuming less energy.
The results have convinced Ruhrmann:
“The RedUnit just runs. We don't have to worry about it. One less thing to deal with.”
By integrating the RedUnit directly into the washing line, Pfeifer & Langen has optimized beet top processing and significantly increased process reliability. In a production environment where downtime is not an option, the RedUnit delivers exactly what matters most: dependable 24/7 operation.
Advantages of the RedUnit
- Reliable grinding of large volumes of sugar beet tops
- Compact design for direct installation into the process line
- Redundant system design for maximum availability
- Large maintenance hatches for fast and safe access
- Higher throughput with lower power consumption
- Robust twin-shaft grinding technology for demanding industrial applications
Benefits for the user
- Continuous 24/7 sugar production throughout the beet campaign
- Significantly reduced downtime
- Increased process reliability
- Lower maintenance effort
- Elimination of additional conveyor equipment
- Improved operational efficiency
- Reliable processing of increasing beet top volumes
