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Digital Re-print - July | August 2011Wear protection underwrites continuity of production

& supply, delivering optimum ROI in demanding animal feed market

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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.

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Grain&feed miinG echnooG July - august 2011 | 19

FEATURE
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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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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.

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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

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