E n g i n e e r e d t o w o r k

Railway AgricultureBiogasWaste waterIndustry

ENGINEERED TO WORK

RotaCut®High performance macerator and solids separator

EFFICIENT PROTECTION, M ACER ATION, TREATMENT

32

RotaCut | Technology

Technology that lets nothing slip by

Efficient maceration of coarse and fibrous

matter in liquid media with effective

protection from foreign objects and heavy

matter – only the RotaCut can offer this.

Invented by Vogelsang over 25 years ago

and continually developed ever since, the

RotaCut is the ideal cost-effective solution

for challenging applications. RotaCut

macerators are used throughout the world,

and thanks to our leadership in know-how

and experience, they are now the best

choice when it comes to reliable and

efficient maceration technology.

FunctionsAll RotaCut models perform two functions

simultaneously, solids reduction and solids

separation. Coarse and fibrous matter

(fibers, hair, bones, wood, etc.) is macerated

by rotating, self-sharpening blades, which

avoids clogging and blockage. The liquid

is also homogenized in the process. Hard

foreign objects and debris (stones, metal

parts, etc.) are separated from the liquid

stream. This prevents damage to down-

stream pumps and equipment. As a result,

RotaCut ensures the smooth flow of liquid

throughout your system.

RotaCut® – guarantee your success with pump systems for media containing fibers, coarse matter and solid objects.

Intelligent solids protection & sludge conditioning.

Maceration technologyThe RotaCut has many applications as a

macerator. Fibrous and coarse matter are

filtered through the cutter head of the

RotaCut with the flow of the pump medium.

The sophisticated cutting-screen geometry

and an innovative blade-guiding system

enable reliable maceration and an extremely

smooth cutting result. Solids such as hair,

rags and other suspended objects are

reduced to a suitable size that can pass

through the system without blockage or

clogging.

Conditioning

The RotaCut is also a very effective

tool for conditioning viscous liquids. It can

be used in several locations throughout a

wastewater treatment plant, in the food

industry, in slaughterhouses, biogas plants

and wherever suspensions with stable con-

sistencies are required. The RotaCut even

effectively macerates hair and industrial

fibers, turning the media into a homoge-

neous suspension.

RotaCut advantages at a glance

• Reliable maceration of fibrous and

coarse materials

• Protection from foreign objects for

all downstream components

• Fluids and suspensions are

homogeneous and less viscous,

requiring less power consumption

by mixing and pumping equipment.

Protection from foreign objectsAn important function of the RotaCut

is protection from foreign objects by

means of an effective heavy material

separator. Stones or metal parts that

cannot be macerated are safely separated

out based on their size or weight and chan-

neled into a collecting container. They can

be easily disposed of later via a cleaning

port. As a result pumps, pipework and

components are effectively protected.

54

RotaCut | Range of Applications

Innovations for maximum cost- ef fec tivenessMaceration technolog y for many applications

Range of applications and mediaWhether compact and mobile or installed in a pipe system, the

diversity of the RotaCut line provides a solution to any problem

in the area of pump and maceration technology as well as

protection from foreign objects. The RotaCut comes in seven

basic versions with different materials, drive units, screen sizes,

rotors and blade shapes.

Around the world, RotaCut macerators have stood the test under

the toughest conditions. Possible fields of application include the

waste water engineering and sewage treatment plants, biogas

plants, paper and cellulose, waste management, agriculture, and

food industries as well as slaughterhouses and rendering facilities.

The RotaCut cost-effectively and efficiently processes a

wide range of media, such as primary and treated sludge,

biosuspensions, food waste and abattoir waste, potato pulp,

oil sludge, and liquid manure. Thanks to its versatility, new

applications are continually emerging.

Examples of common RotaCut applications:

• Prevention of clogging in digestion towers

• Installation in front of a Belt Press, Centrifuge or Gravity

Thickener to ensure that sludge is well conditioned and free of

damaging solids and fragments

• Protection of pumping equipment from foreign objects during

vacuum extraction of small waste water works and sewage stations

• Maceration of abattoir waste and by-products, including

treatment prior to sanitation in accordance with EU Directive

using the Cut&Pump meat plant

• Protection of tanker trucks and distribution technology from

foreign objects and fibers when liquid manure, slurry or brewing

residues are used as organic manure in agriculture

• Digestion and homogenization of biosuspensions in biogas

plants for increased efficiency and gas yield

• Protection of mobile pump systems from foreign objects and

coarse matter

RotaCut is also ideal for any system that

is experiencing build-up or other nagging

problems such as septage/grease receiving,

sludge transfer, primary and secondary

sludge, RAS, WAS, Scum, DAFT, SBR and MBR.

Easy to serviceThe RotaCut is designed to be low

maintenance and easy to service. All

wear parts are easily accessible and can

be replaced in a few easy steps.

Innovative screen geometryOur engineers developed software for

calculating cutting screens with optimum

geometry for all screen sizes and rotational

rates, in many different media. In this way,

we can select a cutting screen for every

task and tailor it precisely to the medium

to be processed. All cutting screens can

be used on both sides. The well-adapted

geometry reduces wear to maximize blade

and screen life.

Blade and rotor constructionThe steel blades of wear-resistant,

Martensitic stainless steel can be quickly

and easily exchanged and are held

against the RotaCut cutting screen by a

self-adjusting cutter head. Thanks to the

sophisticated blade holder in the rotor

there is constant contact between the

blades and cutting screen. Optimized

blade arrangement, combined with the

constant contact between blades and

cutting screen, guarantees vibration-free

motion as well as maximum efficiency

and cost-effectiveness.

Well-thought-out details and a consistent

overall concept make the RotaCut an ideal

solution for a wide range of applications. More

and more users are choosing the RotaCut because

it reliably protects pumps and other components

from foreign objects, fibrous and solid matter and

efficiently processes suspensions.

Always the Right Choice: RotaCut®

76

RotaCut | Designs and Range

Type designation RCQ-20 RC 3000 RC 5000 RC 10000 RCX-48 RCX-58Motor type

Maximum flow rate m3/h gpm

90 396

180 792

300 1320

600 2640

600 2640

750 3300

Geared motorOptional speedOptional motor power

min-1 /rpmkWhp

87 - 320 1.1 - 2.2 1.5 - 3.0

76 - 326 1.5 - 4.0 2.0 - 5.0

73 - 330 1.5 - 7.5 2.0 - 10.0

66 - 319 2.2 - 7.5 3.0 - 10.0

114 - 311 5.5 - 11.0 7.5 - 15.0

94 - 276 7.5 - 15.0 10.0 - 20.0

Hydraulic motor Required oil pressure

Required oil quantity

barpsil/mingpm

50 - 70 725 - 1015

4011

60 - 80 870 - 1160

4512

70 - 100 1015 - 1450

6016

180 - 230 2611 - 3336

7520

Design type overview Inline Inline Cyclone

MXL

Inline Cyclone

MXLM/MX

Compact Compact XL

Inline Cyclone

MXL

Compact Compact XL

Inline Inline

MXL

Cutting screen with available free passage

mm 10/15/20 8/10/1215/20/28

4/8/1015/24/30

4/8/1012/16/2025/34/38

4/8/1012/16/2025/34/38

8/12/1625/34

The right design for ever y task RotaCut Compac t pro

RotaCut Inline This model is easy to integrate into existing systems because

the intake and discharge points are positioned directly opposite

one another. Heavy objects such as stones and metal parts are

separated out and fibrous matter is reliably macerated. This

version is typically used in communal waste water systems and

industrial plants.

RotaCut CycloneThis model is especially suited for applications where heavy objects

such as stones and metal parts must be separated out and a small

amount of fibrous matter must be macerated at the same time.

Typical media include waste water or organic fertilizer.

RotaCut Compact proThe ideal macerator for reliable and cost-effective treatment of

media with large amounts of fibrous matter. Thanks to its robust

design, it can also be used on the discharge side (up to 3 bar is

possible). With the XL design, large amounts of heavy matter in

the medium can be reliably separated out. This type is mainly

used in industry and in biogas plants.

MXL This type is the ideal solution for special requirements in the field

of vehicle construction. It cuts fibers just as reliably as it separates

heavy objects and can be easily installed on a vehicle. Its large

opening provides easy access for service and maintenance, and

heavy objects can be easily removed.

For extreme situations: RotaCut® proFor use in the harshest environments we have developed a

particularly robust version: the RotaCut pro. Thanks to the

modified design and the strengthening of major components,

it is the perfect solution for highly demanding jobs. It achieves

particularly even and homogeneous results. The increased power

enables even greater cutting output in the same space.

Easy to service: RotaCut® RCQThe RotaCut RCQ is characterized by a high degree of serviceability

and user-friendliness. Maintenance and replacement of cutting

knives can be done extremely quickly. Thanks to ACC, the condition

of the blades can be checked during operation without opening

the RotaCut.

We build your RotaCut® to order! We configure every RotaCut to meet the exact needs of your application.

For the many different applications of a RotaCut, there are just as many versions to match: two series, five sizes

in several different designs, a range of configurations and materials as well as different drive unit options.

You define your specific requirements and tasks and we configure a tailored RotaCut macerator for you. High

performance and outstanding ease of maintenance are two things all models have in common.

The powerhouse: RotaCut® RCXWith the models in the RCX series, we have continued to develop

our RotaCut pro concept. They epitomize cost-effective maceration

for rugged applications in tight spaces. The new RCX types feature

extremely robust motors as well as solid and sturdy construction,

allowing for use on the discharge side at up to 6 bar. Reduced wear

and a longer service life mean lower operating costs. All RCX types

feature cartridge seals that require less time to change, enhance

safety and increase serviceability overall.

RotaCut M XLRotaCut RCXRotaCut Inline RotaCut Cyclone

98

ACC advantages at a glance

• No manual blade adjustment required; fully automatic,

uninterrupted operation

• Contact pressure can be readily adjusted to the medium

without interrupting operation

• Low operating costs thanks to minimum wear and low

current consumption

• Optimal results due to consistently high cutting

performance and constant grinding levels

Cut ting screen and blades always func tion in per fec t harmony

RotaCut | Automatic Preloading Unit

ACC – Automatic Cut Control Even pressure at all times

The RotaCut is a macerator that uses direct contact between the

blades and the cutting screen. It reliably macerates long-fiber

materials (such as hair, entangled material, GPS, grass) in media.

ACC ensures high cutting performance at all times:

It automatically adjusts the blades and continuously maintains

the necessary pressure between the blades and the cutting

screen. Manual maintenance is no longer necessary. Furthermore,

the pressure can be externally adapted to suit the medium during

operation.

The automatic control unit maximizes blade and screen life

The ACC adjusts the contact pressure between the blades and

cutting screen to a level as high as is necessary and as low as

possible. This considerably prolongs the service life of the blades.

As a result, ACC is a reliable basis for increased efficiency. It is the

key to largely automated operation in continuous use because

the contact pressure is kept constant until the end of the life

cycle. Once the blades have reached their service life expectancy

limit, a signal is emitted. Within a control facility, this can be

used to inform the operator.

ACC plusWith ACC plus, you can reduce your maintenance and monitoring

costs even further and ensure failure-free operation. This is

because with ACC plus, the RotaCut is monitored online and does

not have to be opened in order to check the blades. An external

display informs the operator of the condition of the blades at all

times. As an additional feature, this can be displayed graphically

by the control system, a useful option if you want to monitor and

check the RotaCut centrally or by remote control. A message

informs you when the blades require changing so that you can

plan replacement part orders and maintenance well in advance.

Optimal pressure between the cutting screen and blades

ACC – stable pressure

Manual preloading system: fluctuating pressure; excessive pres-

sure causes unnecessary wear

+

Optimal pressure-

is the basis for

efficient maceration. ACC®, automatic cutting pressure control,

ensures that this pressure remains even at all times

so you never have to worry about it.

1110

RotaCut | Control Technology

We leave nothing to chance in the service area Whether you require start-up, training or full service with a maintenance contract and a wear parts service package – we provide comprehensive support with our individualized all-round service, helping you to keep your systems running smoothly from the start.

Support and supply from A to ZBecause we are aware that close customer

proximity is essential for our joint success,

we design our services to best meet your

needs. Our international presence in

countries in which we have subsidiaries or

trade partners, Vogelsang service centers

and contractual partners generates an

active dialogue with our customers and

provide reliable support. That means

you get the precise support you need in

Comprehensive ser vices for smooth operation and a long ser vice l ifeTwo details, one prof itable result

LifeGuard – to guarantee a maximum

service life for our products. The service

life of a Vogelsang machine is determined

by specific LifeGuard factors. We take

these factors into consideration and

offer you features that are relevant for

maximum productivity and service life.

Years of experience shared by biogas

plant operators have shown that

LifeGuard services in combination with

our Performance Control Units (PCUs)

lead to optimal results throughout a

long service life without complications.

every phase of our partnership. Our highly

qualified staff makes it possible – expert

consultants and technicians who know

your Vogelsang machines inside and out.

We think aheadThinking ahead in your best interest

begins with our extensive and detailed

product documentation. Spare parts are

available within a short period of time

due to our high degree of vertical

integration in production. In addition,

you will always find an authorized service

partner in your area who can help with

repairs and wear part replacement. The

Vogelsang ServicePack completes the

offer. Whether you need start-up, on-site

training, training at the Vogelsang facility,

or full service support with a maintenance

contract or a wear part service package –

we offer a support program tailored

specifically to your needs.

LifeGuard – Leading viainnovationMaintenance generally results in

downtime as well as expenditures for

personnel and spare parts. We have

therefore developed a concept to limit

service and repair times to a minimum:

PCU – Performance Control UnitPCU is our intelligent control technology. It enables energy-

efficient and autonomous operation because it can monitor not

only the RotaCut itself, but all other upstream and downstream

functions. Based on this data, the individual components

communicate and the throughput rate of the RotaCut is increased.

The PCU registers the load of the RotaCut completely

automatically and regulates the operating parameters to

achieve the optimum result. Malfunctions are detected early,

the appropriate measures implemented and automatically

rectified in plenty of time using the PCU. The unit can also be

easily connected to a higher-level control system via Profibus

(Process Field Bus).

PCU advantages at a glance

• Reduced maintenance due to autonomous operation

• Efficient operation due to fully automatic and situation-

dependent control of operating parameters

• Lower operating costs due to a longer service life

• Reliable operation thanks to automatic fault elimination

• Increased throughput rate

Advantages of the auto reverse at a glance

• Increased efficiency through reduced power requirements

• Lower operating costs

• Reliable operation thanks to automatic blockage elimination

Greater Efficiencythrough Intelligence

Gain a key advantage by using our

intelligent control technology:

efficient, autonomous operation.

LifeGuard factors:

• Self-sharpening cutting unit

• Reversible cutting screen

• Optimized cutting screen geometry

• Self-adjusting blade, optimum

cutting pressure (ACC)

• Auto reverse function

• Optimized blade and rotor design

Auto reverseAuto reverse controls contact with

course and hard extraneous

materials in the RotaCut. The

system recognizes any blockage

in the RotaCut and reverses the

rotational direction of the blade

rotor: a renewed cutting attempt

then occurs from the other side of

the blocking matter. This process is

repeated until the blocking matter

is macerated. Yet another useful

function: regular, automatic

reversal of the direction of rotation

means that the pair of cutting edges

in use at the screen and blades is

always sharp, as it has been ground

on the reverse side beforehand. As

a result, you benefit from optimal

cutting performance with reduced

power consumption.

ENGINEERED TO WORK

Hugo Vogelsang Maschinenbau GmbH Holthöge 10–14 | 49632 Essen/Oldb., Germany Phone: +49 5434 83-0 | Fax: +49 5434 83-10 info@vogelsang-gmbh.com

Our company

Innovation and progress have been

hallmarks of Vogelsang for over 80 years

and have made us a leading global plant

engineering company. Time and time

again we have achieved significant

milestones of progress. Today, we develop,

manufacture and distribute some of the

most innovative and reliable machines

and systems for agriculture, municipali-

ties and industry.

With our overseas subsidiaries and service

centers, we are world-renowned for

advanced engineering and customer-

friendly solutions.

Our product range

We offer solutions for the following

areas:

• Industrial sector

• Waste water treatment

• Biogas

• Railway waste water disposal

• Agriculture

We offer a broad range of products:

• Rotary lobe pumps

• Maceration technology

• Distributors

• Spreading technology

• Supply and disposal systems

• Complete solutions

We also offer customized solutions for

your specialized applications.

How to reach us

Vogelsang is present worldwide. Visit us

online for more information about our

company and wide range of services:

vogelsang.info

We are here to assist you and look forward

to speaking with you.

v o g e l s a n g . i n f o

Cop

yrig

ht©

201

1 H

ugo

Vog

elsa

ng

Mas

chin

enba

u G

mbH

. In

sel

ecte

d co

unt

ries

, Vog

elsa

ng®

, HiF

lo®,

Rot

aCu

t®, A

CC®,

CFC

®,

BioC

rack

® an

d X

Till®

are

regi

ster

ed t

rade

mar

ks o

f Hu

go V

ogel

san

g M

asch

inen

bau

Gm

bH, E

ssen

/Old

b., G

erm

any.

A

ll ri

ghts

rese

rved

, in

clu

din

g th

e ri

ghts

to

all g

raph

ics

and

imag

es. R

otaC

ut®

_EN

_112

0771

1_50

00–

Prin

ted

in G

erm

any

USAVogelsang USA Inc. vogelsangusa.com

Great BritainVogelsang Ltd. vogelsang.co.uk

FranceVogelsang France S.A.R.L.vogelsang.fr

ItalyVogelsang Italy Srlvogelsang-srl.it

PolandVogelsang Poland Sp. z o.o.vogelsang.pl

Romania Vogelsang Romania SRLvogelsang.ro

ChinaVogelsang Mechanical Engineering (Shanghai) Co.vogelsang.com.cn

SpainVogelsang S.L.vogelsang-spain.es

AustraliaVogelsang Pty. Ltd.vogelsang.com.au

IndiaVogelsang India Private Limitedvogelsangindia.com

Czech RepublicVogelsang CZ s.r.o.vogelsang-czech.cz

DenmarkVogelsang A/Svogelsang-as.dk

BrazilVogelsang Brasil Ltda. vogelsang.com.br

MexicoVogelsang De México S. de R.L. de CV.vogelsang.mx

SwedenVogelsang Sverige AB vogelsang.se

MalaysiaVogelsang Malaysiavogelsang.info

Germany – Easter Branch Vogelsang Lutherstadt Eislebenvogelsang-gmbh.com

Product availability, appearance, technical specifications and details are subject to continuous development. All information presented here is therefore subject to change.