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The global demand for animal feedshas never been higher, fuelled
by increasing heavy consump-
tion of meat in China and wealthy
countries in the ASEAN block.
This demand means that continuity of
supply is all important, placing stress all along
the supply chain from processing and trans-
ferring of raw materials and finished product
in animal feed plants, to handling, conveying
and storing the product at ports for onward
shipping.
Handling solid and liquid ingredients
together with binding agents makes the
whole process of producing animal feed
an activity where success depends on theequipment remaining reliable, 24-hours a
day.
However, militating against this is the
nature of animal feeds themselves.
The operations of processing, mixing,
blending, conveying and transferring bring
large volumes of semi-aggressive media into
contact with a variety of plant surfaces. This
media has the capability to wear out hop-
pers, feeders, chutes and mixing equipment
very quickly, resulting in lost production and
excessive maintenance costs.
Whether the feed is conveyed as dried,
mixed or packaged, the process c reates wear
problems.
Depending on the volumes and the oper-ational regime, these will significantly reduce
the value of the processing companys capital
equipment if the plant is not wear protected
for continual operation.
Constant wear, leading to frequent
repairs and maintenance can be avoided if
the correct wear protection is applied. The
result is drastically reduced cost of repairs
on worn-out chutes, ruptured pipelines,
crumbling silos and conveyors.
Eliminating these on-going wear and
repair concerns enables the process to
operate as designed, maximising its efficiency
and the operational teams resource capabil-
ity allowing production efficiency improve-
Wear protection underwrites continuity of
production & supply, delivering optimum ROI
in demanding animal feed marketby John Connolly, MD, Kingfisher Industrial, West Midlands, United Kingdom
Grain&feed miinG echnooG18 | July - august 2011
FEATURE
ment and improved ROI in the animal feed
processing business.
Operational factorsIn common with other bulk materials han-
dling industries, the equipment for processing
and conveying animal feeds needs to cater
for many operational factors. If considered
from the onset, these factors can be catered
for and a design element introduced to com-
pensate for potential wear problems.
Factors such as volumes, loadings, par-
ticle size and shape, viscosity and moisture
content are typical criteria that must be
addressed in order to eliminate potentialproblem wear areas.
Selecting the right liner materials, hopper
design and pipe installation can prevent the
need for replacement and maintenance for
up to 20 years.
No maintenance requirements over
the lifetime of an installation means
reduced risk, reduced cost and more pro-
duction uptime over longer periods all of
which are critically important to improve
the efficiencies of companies that operate
24/7, said John Connolly, managing direc-
tor of the UK wear protection specialist,
Kingfisher Industrial.
Complex and multi-layeredIn quantitative terms the benefits to the
plant user are huge, because maintenance of
process plant and equipment is a complex
and multi-layered operation.
Avoided are the ongoing cost problems
of interruptions to production as a result of
breaking down pipework; the requirement
for specialist labour, and the safety risks
involved with personnel working at height,
performing hot work and lifting operations.
In addition, the tasks of organising access
platforms and plant hire, with their attendant
costs and risks are no longer necessary;
nor are procedures devised for the cleaning-up of spillages that may occur when process
pipework is perforated, thus creating an
environmental issue or potential breach of
legislation.
As a result, the system user benefits from
continuous operational gains, which defray
the cost of the protection system, guarantee-
ing a prompt return on investment.
Using a combination of ceramic, metallic
and polymer lining systems, Kingfisher has
had overwhelming success in protecting
equipment and extending the service life of
bulk materials handling plant.
In many instances, the benefits of protect-
ing plant are threefold: in addition to protect-
ing against wear, the low friction nature of
the lining material reduces energy usage and
increases production by allowing a greater
volume of material to be throughput.
A major benefit of wear protection is
that it can be employed at any time in the
life of a process system, so users do not have
to throw away their existing plant and start
again, says John Connolly.
In addition, because high conveying
speeds and abrasive mate-
rials cause wear of varying
intensity at different points
in process plant systems,it is often the case that
protection need only be applied to areas that
are most vulnerable to wear, further reduc-
ing upfront costs and improving ROI for the
system user.
Protection from inceptionIf a process sy stem is designed with wear
protection from its inception, then overall
equipment costs can often be reduced
because the system chosen to protect the
equipment can often remove the require-
ment to manufacture components using
heavier grades of material.
ALL TYPES OF SILOS INSTALLATIONS TO COVER THE MARKET NEEDS
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Grain&feed miinG echnooG July - august 2011 | 19
FEATURE
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8/6/2019 Wear protection underwrites continuity of production & supply, delivering optimum ROI in demanding animal feed market
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the pipework for the Kingfisher solution
was manufactured and lined with K-BAS
at Kingfishers purpose- built factory in the
West Midlands, and then delivered to site
for final assembly. Assembly of the pipework
was carried out, in this instance, because of
timing, by the feed suppliers own mainte-
nance personnel. However, Kingfisher gener-
ally takes full turnkey responsibility in the
wear protection projects that the company
handles.
We provide a full turnkey service with
our wear protection systems, including com-
plete installation and commissioning, said
John Connolly. Our customers generally like
this approach, as it keeps everything under
one roof, giving them the security of a single
source supply from a partner company theycan trust.
About Kingfisher IndustrialKingfisher Industrial provides wear solu-
tions for process plant used to convey, proc-
ess or store bulk solid materials, in either
dry or hydraulic states. With its range of
ceramic, metallic and polymer protection sys-
tems, Kingfisher can overcome wear problems;
engineering suitable protection systems that
can add many years of life to a plant, and in
some cases outlast the design life of a process
completely.
These solutions cater for the operat-
ing criteria, budget and life cycle of either
new equipment - particularly when initially
installed - or existing equipment, which can
be retrofitted with a protection system to
add to its current asset value.
equipment against unplanned main-
tenance and costly downtime are
evidenced by a 2003 application of
the technology at a major animal feed
supplier in Shropshire.
The company was experiencing
constant problems of perforation in
pipes, along which abrasive animal
feedstuffs were conveyed pneumatically at
high speed. A number of solutions were
tried, but the frequency of replacements
and downtime resulting from these led to
an approach to Kingfisher Industrial, which
advised another approach, based upon the
companys ceramic K-Bas Cast Basalt Lining
System.
With a hardness rating of approximately
eight on the MOHS hardness scale, K-BASoffers key benefits, such as resistance
to friction-
induced
abrasion
and ero-
sion in
plant
where bulk
solids are
conveyed,
stored
and proc-
essed by
mechanical,
pneumatic
or hydraulic means. In addition, K-BAS
is a relatively inexpensive form of wear
protection, which is corrosion resistance,
and offers the additional advantage ofpromoting material flow.
K-BAS is one of the many liners we offer,
said John Connolly. There is no one-size-fits-all
philosophy in respect of wear protection, thats
why we always carefully analyse all aspects of
the equipment, site and surrounding environ-
ment before we put a firm solution proposal
before our customer. What we are aiming
to achieve is the longest possible operating
life from an installation, to payback the initial
investment many times over. Our success is
evidenced by installations such as the one in
Shropshire, which is now in its eighth year of
operation, with no problems to report.
In the case of the Shropshire installation,
In addition, involving a wear specialist
such as Kingfisher at the design stage of proc-
ess conveying equipment can streamline the
design, optimising process efficiency through
reduced turbulence and improved material
flow, at the same time ultimately delivering
improved service life.
Kingfisher has produced a graphic to
highlight the benefits of its whole life cost
argument (see Table 1). The graphic com-pares the ongoing costs associated with
equipment and installations that do not ben-
efit from wear protection, with the one-off
(i.e. purchase) costs of enhanced protection,
highlighting the continuous operational gainsof the latter investment strategy.
The thrust of the argument is clear
when considering the typical example of an
enclosed pipework system for conveying
bulk materials. The system is wear protected,
and so is able to provide up to 20-years of
life. With this one-off approach, the system
user has little or no maintenance require-
ments over the lifetime of the installation.
He does not have the ongoing cost prob-
lem say every 4-years - of breaking the
pipework system down - and of interrupting
production in the process.
The long term benefits of wear protec-
tion as a safeguard for animal feed processing
MoreinforMation:
John ConnollyManaging Director
Kingfisher Industrial
Cradley Business ParkOverend Road
Cradley Heath
West Midlands B64 7DWUnited Kingdom
Tel: +44 1384 410777
Email: [email protected]
Table 1
Grain&feed miinG echnooG20 | July - august 2011
FEATURE
Grain&feed miinG echnooG July - august 2011 | 21
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VIGAN manufactures bulk materials handling equipment:
Mobile pneumatic conveyors or vacuvators.
Pneumatic continuous barge unloaders and mechanical barge loaders.
Mechanical and pneumatic continuous ship unloaders for vessels up topost-Panamax.
Mechanical loaders for any size of ships.
as well as complete storage systems in ports and the agricultural industries.
From project design to complete turnkey bulk handling solutions
and port terminals with reliable and cost effective equipment.
DEKHEILA PORTin Egypt (Africa silos) :2 mobile machineswith conveyors
2 x 250 tons/hour
HAUTRAGEin Belgium :1 pneumatic tower
300 tons/hour
PORT SUDAN1 ship unloader600 tons/hour
An afliate company of VAN DE WIELE group.
Latest references
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Topical liquids used in the extrusion process of pet food
manufacturing are sticky and particularly hard to clean, especially
when they congeal in colder weather.
Before changing to Tapco urethane
buckets, wed sometimes have to
stop production and clean twice a
day, Jeff Bowman, Extrusion Plant
Manager, Spectrum Feed Services,Ltd. says. That meant allocating
2-3 hours for two staff members to
hand scrape every bucket on our 60-foot-tall legs, each time.
Trust me, nobody liked THAT job.
Cross-contamination was also a constant concern and led to
more rework to maintain product quality.
After consulting with Tapco, Spectrum had Proactive Industrial
Maintenance replace the existing buckets with FDA-compliant
urethane resin CC-HD buckets. Tapco urethane buckets resist
product adhesion and flex to release caked-on build-up.
Now sticky extruded pellets and kibble slide right out of Tapco
urethane buckets, Bowman says. We went from scraping buckets
twice a day, to cleaning on a weekly schedule, without concerns
of cross-contamination, Bowman says. The cleaning process isfaster and easier, too, which is important when youre
processing 140 tons a week.
Need help out of a sticky situation? Talk to Tapco and
find out why 75% of design engineers, contractors
and bucket elevator manufacturers* trust Tapco
buckets to keep business moving.
ELEVATOR BUCKETS - ELEVATOR BOLTS
Tel.: +1 314 739 9191 +1 800 AT TAPCO (+1 800 288 2726) Fax: +1 314 739 5880 Email: [email protected]
www.tapcoinc.com
Sticky extruded pellets and kibbleslide right out of Tapco urethane
buckets. We clean less often
now and worry a lot less about
cross-contamination.Jeff BowmanExtrusion Plant Manager
GREAT CANADIAN PET FOOD CO./DIVISIONOF SPECTRUM
FEED SERVICES, LTD.Moorefield, Ontario, Canada
*Grain Journal, Country Journal Publishing Co., Inc., Decatur, Illinois, U.S.A. 2011 Tapco Inc. All rights reserved.
STYLECC-HD
Severe Duty Urethane Elevator Bucket
How Tapco Helped Spectrum Feed ServicesOvercome a Sticky Situation
FANGEDHEAD
Elevator Bolt
Andy GingrichOwner/Millwright
PROACTIVE INDUSTRIAL MAINTENANCEElmira, Ontario, Canada
St. Louis, Missouri USA
UNORMAK DEG. MAK. IML. SAN. ve TIC. LTD. Sti
Konya Organize Sanayi Blgesi 7. Sokak No: 5/1Konya / TRKIYETel: +90 332 2391016Fax: +90 332 2391348e-mail: [email protected]: www.unormak.com.tr
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