RotaCut
Wet cutter with integrated heavy material separator
- Reliably macerates fibers and foreign matter in liquid media
- Protects downstream system components from damage caused by foreign matter
- Prevents blockages and clogging of pumps, fittings and pipe systems
- Reduces the viscosity and homogenizes liquids and suspensions
- Prevents floating layers
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Agriculture
RotaCut – the cutter for mobile applications
The more flowable and homogeneous the liquid manure and digestates are, the more effectively they can be used as organic fertilizers. The Vogelsang RotaCut shreds the medium as well as coarse and fibrous matter contained in the liquid manure. This optimizes the flow characteristics of the liquid manure while preventing blockages, such as in the spreading system. The foreign matter contained in the medium is separated out. RotaCut provides effective pump protection for the liquid manure transport vehicle. The direct contact between the blades and cutting screen makes this efficient cutter the perfect solution for highly precise cutting performance. The opening on the RotaCut has been designed to be as large as possible to enable easy access for service and maintenance. It's also easy to re-move the separated heavy material. With the RotaCut MXL, Vogelsang offers the perfect solution for the unique requirements of mobile applications, such as on tankers and self-propelled vehicles. This compact unit ensures a homogeneous, easily dispensable liquid manure suspension. This results in even distribution of the nutrients contained within. At the same time, this efficiently protects the entire spreading technology system. Innovative technologies such as optimized cutting screen geometry or use of the Automatic Cut Control (ACC) for self-adjusting blades and optimal cutting pressure make the Vogelsang RotaCut a reliable as well as economical shredding system.
Biogas
RotaCut – economical substrate disintegration and reliable foreign matter protection
The RotaCut has proven the optimal solution countless times whenever foreign matter is disrupting biogas plant operation or long-fiber solid matter in the suspension is causing problems. The integrated heavy material separator (stone catcher) separates out metal parts and stones. At the same time, the RotaCut cuts foreign matter such as wood pieces and branches, and is ideal for disintegrating fibrous foreign matter such as straw. Solid matter composed of long fibers, such as dung, straw and grass silage, as well as car grass, is finely shredded. In this way, the RotaCut protects pumps and other components of the biogas plant from damage caused by foreign matter while also preventing clogging. The reliable disintegration of long-fiber fibrous matter with the RotaCut simultaneously prevents the formation of floating layers in the digester of the biogas plant. This reduces the suspension's viscosity, which in turn lessens the load on the mixers, reduces power consumption and shortens the needed mixer run time in many biogas plants. The comprehensive model range as well as the numerous features and options enable the cutter to be used in a wide variety of positions within the biogas plant. For instance, the RotaCut can treat both the liquid suspension and/or recirculated material before mashing within the scope of liquid feeding, as well as disintegrate the freshly mashed suspension as a first step even before the digester. Moreover, the RotaCut can be easily integrated anywhere that pumping processes are required within the biogas plant. For example, for transfer from the digester into the post digester and/or into final storage, and for return flow of the recirculated material. However the compact and easy to maintain cutter can also be easily integrated into the pipe system for digester circulation and/or when external heating is used – or additionally for supplying fresh liquid manure upstream of the separator. There is at least one place in every biogas plant to integrate the RotaCut.
Industry
RotaCut – reliable cutter for industrial applications
The RotaCut, our cutter with an integrated heavy material separator, can be used in a wide range of industrial applications. This cutter offers direct contact between the blades and cutting screen, which allows it to deliver defined cutting performance, which is a major advantage for processing fibrous materials. Moreover, as the RotaCut simultaneously homogenizes the medium, it offers much more than merely pump protection for downstream systems. Medium that has been disintegrated in this manner an also be easily used in additional processes.
In industrial applications, the RotaCut is usually used together with other Vogelsang products, such as rotary lobe pumps, progressive cavity pumps or other cutters, such as the XRipper. For example, in applications involving food wastes, not all materials are suitable for being pumped onward directly after an initial shredding step. Fish, meat and vegetable waste, in particular, often contain coarse fibrous materials that are separated in a heavy material separator.
Two RotaCut models in particular have proven themselves effective in industrial applications: The RotaCut RCX is used in abattoirs as part of the RedUnit in order to meet the requirements of the EU directive on hygiene. Thanks to its compact design and reliable shredding performance, the RotaCut MXL is used on tankers to protect the pumps from foreign matter.
With features and options such as Automatic Cut Control (ACC) and Auto-Reverse function, the cutter is a key product for the shredding required in industrial applications.
Wastewater
RotaCut – reliable and effective treatment of waste water or sludge
If fibers and entanglements in wastewater and sludge are causing problems, the RotaCut is the solution. With its contact-based cutting principle the cutter even reliably shreds hair and the finest fibers of (Q-Tips). Foreign matter contained in waste water or sludge is also reliably separated in the RotaCut's integrated heavy material separator (stone catcher). In this way, the cutter protects pumps and other components in the sewage treatment plant and sewers from damage caused by foreign matter while also preventing clogging. At the same time, the sludge is homogenized, which significantly reduces the costs and effort needed for sludge thickening and sludge dewatering. Thanks to the disintegration of the sludge performed by the RotaCut, the decanter and separators run more evenly, free of disruption, to deliver superior dewatering performance. Integrated into the supply line of the digestion tower, the cutter finely shreds hair and fibers. The RotaCut therefore prevents the formation of entanglements and floating layers, while also preventing disruptions during circulation or sludge removal. Specially adapted designs and sizes are available to make integration into existing sewage treatment plants as straightforward as possible. Comprehensive features and options enable individual adjustment to the on-site situation at the respective sewage treatment plant. Thanks to the RotaCut's user-friendly service concept, maintenance and parts replacement can be performed quickly on-site. Simply pivot out the cutter head for optimal access; wear parts can then be easily replaced by sewage treatment plant staff or by a service partner.
Features
Options
The medium flows steadily through the RotaCut. Foreign matter (stones, metal parts, etc.) is separated out based on its size or weight and can be easily disposed of later via a cleaning port. All floating and suspended substances within the medium (fibers, hair, bones, wood, etc.) are transported to the cutting screen by the liquid current and are reliably shredded by rotating, self-sharpening blades – even hair and industrial fibers are no problem. Liquids containing solid matter are transformed into pumpable, homogeneous suspensions. This makes the RotaCut an effective tool for homogenizing heterogeneous media, such as is increasingly required in the food industry, abattoirs and biogas plants. Another important function of the RotaCut is effective heavy material separation. Stones or metal parts, etc., that cannot be shredded are safely retained and channeled into a collecting container. The RotaCut thereby effectively protects pumps, pipe systems and biogas plant parts from damage due to foreign matter.
Hydraulic or geared motors adapted for the prevailing conditions of the application are used to drive the cutter. A selection of geared motors with various power ratings and different speeds are available for every type, so the RotaCut can always be individually adapted to the respective application. The perfect motor is available for every task, from protection against fibers and coarse matter through to fine, homogeneous disintegration of a suspension. Suitable cutting screens and blade rotors are available for individual adjustment of the size-reduction ratio from simple system protection through to homogeneous treatment.
In addition to shredding, heavy material separating – and therefore protection against foreign matter – is the most important function of the RotaCut in many applications. Depending on the medium and focus of the task, our customers can select from different available designs, each with individual characteristics. The following types are available for the individual series.
Inline
- Intake and discharge directly opposite – therefore "in (a) line"
- Pressure max. 2 bar (depending on size)
- For media with moderate fiber and solids content
- For media with low heavy material content
- Primarily used in: waste water technology, sewage treatment plants, industrial applications
MXL
- Simple to integrate onto vehicles
- Service and maintenance access via large service flap
- Pressure max. 0.5 bar
- For media with low to moderate fiber and solids content
- For media with moderate to high heavy material content
- High separation performance
- For installation on tankers
Compact XL
- For applications that require high cutting and separation performance
- Pressure max. 4 bar
- For media with moderate fiber and solids content
- For media with high heavy material content
- Used in biogas plants and industrial applications
BioCut
- The medium and fibers flow directly toward the cutting screen.
- For applications that require high cutting performance
- Pressure max. 2 bar
- For media with moderate to high fiber and solids content
- For media with low heavy material content
- Used in biogas plants
RCX
- Universal design for high throughput
- Service and maintenance access via pivoting service flap
- Pressure max. 6 bar
- For media with moderate to high fiber and solids content
- Optionally available with heavy material separator
- Used in biogas plants, industrial applications and waste water technology
RotaCut MXL
The solution for tankers
In developing the RotaCut MXL, special attention was paid to taking into account the exigencies of vehicle design. The design was specially developed for mobile use on tankers, delivers throughput up to 750 m3/h and can be quickly and easily integrated into the vehicle. The RotaCut also performs a range of essential functions for mobile applications: Foreign matter such as stones and metal parts are reliably retained in the generously dimensioned heavy material separator. When pumping liquid manure, for example, the RotaCut MXL shreds the coarse matter and fibrous matter, thereby homogenizing the entire medium. Drive power is usually provided by the hydraulics available on most vehicles. After opening the generously dimensioned service flap, the separated heavy material can be easily removed, and access to the cutter head for service and maintenance is enabled.
Applications
- Disposal vehicles
- Liquid manure
- Waste water
- Fecal matter
- Tankers
- Suspensions
- Sludges
Technical Specifications
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Case Studies RotaCut
RotaCut® 5000pro Compact XL: Reliable protection against heavy material with greater efficiency
Problem: Pump damage due to foreign matter, insufficient gas yield from the biogas plant
Solution: Vogelsang RotaCut® 5000pro Compact XL
RotaCut: Running a biogas plant efficiently and reliably
Problem: Thick floating layers and clogging in the external heater
Solution: Vogelsang RotaCut® with AutomaticCutControl (ACC®)
RotaCut: Significantly reduced energy costs for mixing
Problem: High energy requirements for mixing the digester in the Duderstadt biogas plant
Solution: Vogelsang RotaCut® pro
RotaCut RC3000 Inline: Cost-effective alternative to swing-hammer mills
Problem: Low-cost processing of potato pulp for use as feeding stuff
Solution: Vogelsang RotaCut® 3000 Inline
RotaCut RC5000 Inline: Trouble free dewatering
Problem: Malfunctions of centrifuges in dewatering
Solution: Vogelsang-RotaCut® RC 5000 Inline with ACC
RotaCut Inline: Efficient and reliable feeding of digestion tower
Problem: High operation costs for feeding the digestion tower in the Willstaett sewage treatment plant
Solution: Vogelsang RotaCut® Inline
RotaCut RC Inline: Trouble-free digester recirculation
Problem: Daily clogging of the recirculation pumps
Solution: Vogelsang RotaCut Inline
RotaCut RC 5000 Inline: Trouble free fecal sludge receiving
Problem: Blockages and damage to the displacement pumps of the septage receiving station
Solution: Vogelsang RotaCut RC 5000 Inline