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

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.

To Agricultural Technology World

Biogas

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.

To Biogas World

Industry

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.

To Industry World

Wastewater

Wastewater

RotaCut – reliable and effective treatment of waste water or sludge

If fibers and entanglements in waste water 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.

To Wastewater World

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Features

Separation of stones and metal parts is important for ensuring smooth operation of the cutter itself as well as of the downstream pumps and components, and also to prevent damage and blockages they may cause. Each RotaCut therefore has an integrated heavy material separator that can be individually adjusted.
Vogelsang uses its proprietary software to develop cutting screens with optimized geometry for every size-reduction ratio. For operators, this means the best geometry at all times for smooth running, with minimal wear. The cutting screens are produced from wear-resistant special steel and offer twice the performance since they are reversible.
The cutting screens are exposed to high loads in cutters like the RotaCut. This is why in the RotaCut, they are not merely supported at several points, but rather their entire surface lies on a stable holder. This reduces deformation of the cutting screen and enables easy and energy-saving cutting across the entire surface.
Cutting blades and rotors have a decisive impact on the RotaCut's cutting performance. The asymmetric blade rotors we developed in-house deliver optimal shredding performance with minimal wear. The mobile bearing of the cutting blade ensures continuous contact between the cutting screen and blade – a solid foundation for reliable cutting of even the finest fibers.
Shredding media with a high solids content in a small space places a great strain on the cutting screens. This is why we have optimized the holder on both the Pro and RCX series: the cutting screen is additionally stabilized by a central support. This minimizes deformation of the cutting screen and also enables efficient cutting despite high load operation.
Each RotaCut has a blade adjustment function that ensures that the cutting blade and screen are always in direct contact. This contact is what enables reliable shredding of even the finest, long-fiber fibrous matter, such as hair, industrial fibers and grass entanglements.
All RotaCut products feature a maintenance and easy to maintain design. Just a few motions are required to gain access to the cutting tools, which can be replaced on-site. The RotaCut is ready for use again in no time at all. The RotaCut does not need to be removed nor the cutter head disassembled.

Options

The hole pattern of the cutting screens, along with the number of cuts, is decisive for the size-reduction ratio. To meet the requirements of every situation, we offer cutting screens for the RotaCut, depending on the size, with free passage from 4 mm to 50 mm. Stainless steel versions are available for aggressive media.
The Automatic Cut Control (ACC) automatically adjusts the RotaCut's blades and maintains constant pressure between the cutting screen and blade. Moreover, the pressure can be adjusted during operation; as high as necessary and as low as possible. This extends the lifetime of the cutting blades and screen, and enables automatic operation.
ACCplus further reduces the cost of maintenance and monitoring of the cutter. It monitors the cutting blade status online and displays it on an external display. This means it's no longer necessary to place the cutter out of service and open it to determine the cutting blade status. Additionally, this information can be processed and displayed by the (central) control and/or remote control.
The Auto-Reverse function detects blockages, such as those caused by coarse disruptive matter, and initiates corrective action. By periodically reversing, the function further ensures that a pair of sharp cutting edges is always used while dull ones are sharpened on the opposite site. This delivers optimal cutting performance with reduced power consumption.
For smooth operation of many biogas plants, reliable foreign matter separation of stones and metal parts is a must, in addition to shredding. The adapted design of the heavy material separator is crucial. It has to be compatible with the requirements for the respective application as well as shredding. The RotaCut offers the most comprehensive selection of heavy material separators.
The Debris Removal System (DRS) available for the RotaCut RCX series enables regular removal of separated heavy material during ongoing operation. 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 80%.
The housing of the RotaCut is made of steel and is completely galvanized. Alternatively, the exterior is painted while the interior is coated with a highly chemically-resistant epoxy resin. Stainless steel variants are available for particularly aggressive applications. Cutting screens and blades are also available in steel and/or stainless steel versions.

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

 

Cyclone

  • The medium flow in from the side, rotates, and flow up through the cutter head.
  • For applications that require high separation performance
  • Pressure max. 0.5 bar
  • For media with low to moderate fiber and solids content
  • For media with moderate to high heavy material content
  • Primarily for applications in the agricultural sector as well as in waste water technology

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

  • For applications that require high cutting performance
  • Pressure max. 4 bar
  • For media with high fiber and solids content
  • For media with low heavy material content
  • Primarily used in: biogas plants and industrial applications

Compact XL

  • For applications that require high cutting and separation performance
  • Pressure max. 3 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


Case Studies RotaCut

Case study - Biogas plant Hofmann - RotaCut with ACC

RotaCut: Running a biogas plant efficiently and reliably

Problem: Thick floating layers and clogging in the external heater
Solution: Vogelsang RotaCut® with AutomaticCutControl (ACC®)

to report

Case study - Duderstadt biogas plant - RotaCut pro

RotaCut: Significantly reduced energy costs for mixing

Problem: High energy requirements for mixing the digester in the Duderstadt biogas plant
Solution: Vogelsang RotaCut® pro

to report

Case study - Gebr. Alpen Biogas GmbH & Co. KG - EnergyJet and RCX-58G

EnergyJet and RotaCut RCX-58G: More efficient biogas plant operation through reliable solid matter feeding

Problem: A solid matter feeding system that is incompatible with a high proportion of grass silage
Solution: Easy digester feeding with well prepared grass silage with EnergyJet® and RotaCut RCX-58G®

to report

Case Study - Potato processing industry - RotaCut RC3000 Inline

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

to report

Case Study - hanseWasser Bremen GmbH - RotaCut RC5000 Inline

RotaCut RC5000 Inline: Troublefree dewatering

Problem: Malfunctions of centrifuges in dewatering
Solution: Vogelsang-RotaCut® RC 5000 Inline with ACC

to report

Case Study - Sewage treatment plant in Krefeld - RotaCut RC5000 Inline

RotaCut RC5000 Inline: Foreign bodies, coarse materials and fibres in the sewage

Problem: Blockages and damage to the displacement pumps of the sewage station
Solution: VOGELSANG RotaCut® 5000 Inline

to report

Case Study - Willstaett sewage treatment plant - RotaCut Inline

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

to report


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