BioCut RC5000 / VX136-70Q: Trouble-free pumping of a blood/feather mixture
RedUnit: saving costs and energy consumption in a slaughtering plant

Problem

High energy consumption and low efficiency

Solution

Retrofitting of the RedUnit XRL186-520QD (pompa monovite CC44 M1)

1. The customer

The company is a cooperative that operates in the agri-food sector of cured meats specializing in salami, and beef and pork fresh meats.
The company mainly operates in two factories. One factory is located in Sasso Morelli, Imola (Bologna) and is dedicated to the production of cured meats. The other factory is in Faenza (Ravenna) where slaughtering and sectioning of cattle and pigs are carried out using the most advanced operating procedures to guarantee animal welfare and high quality standards in the transformation and processing system.
In order to operate with sensitivity for the environmental sustainability, the company invested in the building of a biogas plant for the production of electric power and heat from by-products.
The project was developed with an analysis carried out by data from the annual feeding plan. The aim of the project is to produce electricity through the valorization of by-products and slaughterhouse waste that are anaerobically destructed to produce biogas (methane) and therefore, generate electricity and heat through a cogeneration system.

2. The problem

Before being sent to the pasteurizer, the slaughtering waste (mainly pigs intestinal packs) are shredded by a shredding system and pumped by a volumetric pump.
The process also includes the unloading of the material into a hopper (see picture above) and then into a grinder system by a screw. Here, the positive displacement pump conveys the material into a pasteurizer in which follows the required process before being sent to the digester.
The previous installed system has a shredding system composed by a classic meat grinder (similar to a mill) with an installed power above 35 kW. Then, this machine was connected to a cavity pump that conveyed the material into the pasteurizer (see the picture below).
This system was not optimal and functional to the company working needs and it created different operational and economic problems, regarding

  • Installed capacity and consumptions
  • Working mass flow rate below the value required (about 5 tons/hour)
  • NOT clean system
  • Non-Optimal working efficiency (system not versatile and reactive to any foreign bodies)
  • Required continual maintenance and high time-labor costs

Before being sent to the pasteurizer, the slaughter waste (mainly pigs’ intestinal packs) is shredded by a shredding system and pumped by a volumetric pump.
The process also includes the unloading of the material into a hopper (see picture above) and then into a grinder system by a screw. Here, the positive displacement pump conveys the material into a pasteurizer in which follows the required process before being sent to the digester.
The previous installed system had a shredding unit composed of a classic meat grinder (similar to a mill) with an installed power over 35 kW. This machine was connected to a cavity pump that conveyed the material into the pasteurizer (see the picture below).
This system was not optimal and functional for the company’s working needs and it created different operational and economic problems, regarding:

  • Installed capacity and consumptions
  • Working mass flow rate below the value required (about 5 tons/hour)
  • NOT clean system
  • Nonoptimal working efficiency (system not versatile and reactive to any foreign bodies)
  • Required continual maintenance and high time-labor costs

3. The solution

The solution currently adopted involves the use of our RedUnit XRL 186-520QD with the CC44 M1 cavity pump . This combined system was easily included in the plant without needing any changes to the whole plant layout and significant investment costs. The installed power is now the following:

  • XRipper shredder XRL: 15 kW
  • CC pump: 5.5 kW

A panel with PLC and software developed by Vogelsang that was perfectly interfaced with the operation of the entire biogas plant, was also installed creating a harmonious system. No start up and control operations are now required continuously.

The machine is insured from foreign bodies or material which can damage it through a warning system that checks its correct functioning in the set working parameters.

Bullet points – Advantages and benefits:

  • Installed capacity and consumptions reduced
  • Work mass flow more satisfactory (about 15-20 tons/hour)
  • Machine working hours is reduced
  • Clean and hygienic system
  • Optimal working efficiency (versatile system and reactive to the foreign bodies)
  • Constant ordinary maintenance and time-labor costs reduced

Benefits in the biogas plant

The installation of the RedUnit machine provides the following benefits in the management of the biogas plant:

  • By means of an automated process reduces the working time for the biogas plant staff where they can modulate the machine work according to the application needs and  quickly recognize any problems and react on it immediately
  • The QuickService concept allows easy maintenance, reduced service costs and less working time
  • The possibility of regulating the flow  allows to input the precise quantity of  material required in the following steps of the process, improves the recipe for the digester feeding and protects the equipment downstream from any overloads or blockages
  • High energy-consumption savings of the plant. Thanks to a more efficient technology, the plant has a higher gas yield and lower energy expenditure
  • The whole process can be controlled remotely (not possible with the previous system)

These benefits makes the customer very satisfied of the current plant layout compared to the previous one. The customer says: “We have a higher control of all the system which is thanks to the automation technology and the responsiveness of the RedUnit, as well as the energy and labor cost savings “.

Advantages of the Vogelsang Vogelsang BioCut

  • Reliable shredding of fibrous and coarse matter in a medium
  • Pulsation-free pumping thanks to HiFlo rotary lobes
  • Highly service and maintenance friendly thanks to QuickService design
  • Compact design

Benefits for the user

  • BENEFIT 1
  • BENEFIT 2
  • BENEFIT 3
  • BENEFIT 4
  • BENEFIT 5 (max. 5)
/ /