The global demand for animal feeds has never been higher, fuelled by increasing heavy consumption of meat in China and wealthy countries in the ASEAN block.

1. Digital Re-print - July | August 2011
Wear protection underwrites continuity of production
& supply, delivering optimum ROI in demanding animal feed market
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2. FEATURE FEATURE
ment and improved ROI in the animal feed Complex and multi-layered ing plant are threefold: in addition to protect-
processing business. In quantitative terms the benefits to the ing against wear, the low friction nature of
plant user are huge, because maintenance of the lining material reduces energy usage and
Operational factors process plant and equipment is a complex increases production by allowing a greater
In common with other bulk materials han- and multi-layered operation. volume of material to be throughput.
dling industries, the equipment for processing Avoided are the ongoing cost problems “A major benefit of wear protection is
and conveying animal feeds needs to cater of interruptions to production as a result of that it can be employed at any time in the
for many operational factors. If considered breaking down pipework; the requirement life of a process system, so users do not have
from the onset, these factors can be catered for specialist labour, and the safety risks to throw away their existing plant and start
for and a design element introduced to com- involved with personnel working at height, again,” says John Connolly.
pensate for potential wear problems. performing hot work and lifting operations. “In addition, because high conveying
Factors such as volumes, loadings, par- In addition, the tasks of organising access speeds and abrasive mate-
ticle size and shape, viscosity and moisture platforms and plant hire, with their attendant rials cause wear of varying
content are typical criteria that must be costs – and risks – are no longer necessary; intensity at different points
addressed in order to eliminate potential nor are procedures devised for the cleaning- in process plant systems,
problem wear areas. up of spillages that may occur when process it is often the case that
Selecting the right liner materials, hopper pipework is perforated, thus creating an protection need only be applied to areas that
design and pipe installation can prevent the environmental issue or potential breach of are most vulnerable to wear, further reduc-
need for replacement and maintenance for legislation. ing upfront costs and improving ROI for the
up to 20 years. As a result, the system user benefits from system user.”
“No maintenance requirements over continuous operational gains, which defray
the lifetime of an installation means the cost of the protection system, guarantee- Protection from inception
reduced risk, reduced cost and more pro- ing a prompt return on investment. If a process system is designed with wear
duction uptime over longer periods – all of Using a combination of ceramic, metallic protection from its inception, then overall
which are critically important to improve and polymer lining systems, Kingfisher has equipment costs can often be reduced
the efficiencies of companies that operate had overwhelming success in protecting because the system chosen to protect the
24/7,” said John Connolly, managing direc- equipment and extending the service life of equipment can often remove the require-
tor of the UK wear protection specialist, bulk materials handling plant. ment to manufacture components using
Kingfisher Industrial. In many instances, the benefits of protect- heavier grades of material.
Wear protection underwrites continuity of
production & supply, delivering optimum ROI
in demanding animal feed market
by John Connolly, MD, Kingfisher Industrial, West Midlands, United Kingdom
symaga_quarter page_IAFD2011 13/5/11 10:09 Page 1
www.symaga.com
T
he global demand for animal feeds an activity where success depends on the Depending on the volumes and the oper-
has never been higher, fuelled equipment remaining reliable, 24-hours a ational regime, these will significantly reduce
by increasing heavy consump- day. the value of the processing company’s capital
tion of meat in China and wealthy However, militating against this is the equipment if the plant is not wear protected
"Over 20 years of experience in the design, construction
countries in the ASEAN block. nature of animal feeds themselves. for continual operation. and supply of storage solutions, worldwide"
The operations of processing, mixing, Constant wear, leading to frequent
This demand means that continuity of blending, conveying and transferring bring repairs and maintenance can be avoided if
ALL TYPES OF SILOS INSTALLATIONS TO COVER THE MARKET NEEDS
supply is all important, placing stress all along large volumes of semi-aggressive media into the correct wear protection is applied. The
the supply chain from processing and trans- contact with a variety of plant surfaces. This result is drastically reduced cost of repairs
Silos for seeds, cereals, malts, oil seeds (soya, sunflower, rape, ...), pellets, meals, rices, and in
ferring of raw materials and finished product media has the capability to wear out hop- on worn-out chutes, ruptured pipelines,
general, products for agriculture, agrifood industry, biofuels, and biomass (wood pellets, ...)
in animal feed plants, to handling, conveying pers, feeders, chutes and mixing equipment crumbling silos and conveyors.
and storing the product at ports for onward very quickly, resulting in lost production and Eliminating these on-going wear and
Ctra. De Arenas, km 2,300, 13210 Villarta de San Juan. Cludad Real - Espana
shipping. excessive maintenance costs. repair concerns enables the process to
www.symaga.com antonio.benitez@symaga.com
Handling solid and liquid ingredients Whether the feed is conveyed as dried, operate as designed, maximising its efficiency
Phone: +34 91 726 43 04/ +34 926 64 04 75 Fax: +34 91 361 15 94/ +34 926 64 02 94
together with binding agents makes the mixed or packaged, the process creates wear and the operational team’s resource capabil-
whole process of producing animal feed problems. ity allowing production efficiency improve-
18 | July - august 2011 Grain &feed millinG technoloGy Grain &feed millinG technoloGy July - august 2011 | 19

3. FEATURE
equipment against unplanned main- the pipework for the Kingfisher solution
tenance and costly downtime are was manufactured and lined with K-BAS
evidenced by a 2003 application of at Kingfisher’s purpose- built factory in the
the technology at a major animal feed West Midlands, and then delivered to site
supplier in Shropshire. for final assembly. Assembly of the pipework
The company was experiencing was carried out, in this instance, because of
constant problems of perforation in timing, by the feed supplier’s own mainte-
pipes, along which abrasive animal nance personnel. However, Kingfisher gener-
In addition, involving a wear specialist feedstuffs were conveyed pneumatically at ally takes full turnkey responsibility in the
such as Kingfisher at the design stage of proc- high speed. A number of solutions were wear protection projects that the company
ess conveying equipment can streamline the tried, but the frequency of replacements handles.
design, optimising process efficiency through and downtime resulting from these led to “We provide a full turnkey service with
reduced turbulence and improved material an approach to Kingfisher Industrial, which our wear protection systems, including com-
flow, at the same time ultimately delivering advised another approach, based upon the plete installation and commissioning,” said
improved service life. company’s ceramic K-Bas Cast Basalt Lining John Connolly. “Our customers generally like
Kingfisher has produced a graphic to System. this approach, as it ‘keeps everything under
highlight the benefits of its whole life cost With a hardness rating of approximately one roof’, giving them the security of a single
argument (see Table 1). The graphic com- eight on the MOHS hardness scale, K-BAS source supply from a partner company they
pares the ongoing costs associated with offers key benefits, such as resistance can trust.”
to friction-
induced About Kingfisher Industrial
e b site
ur w
Table 1
abrasion Kingfisher Industrial provides wear solu-
and ero- tions for process plant used to convey, proc-
Vi sit o gan.com
vi
www.
sion in ess or store bulk solid materials, in either
plant dry or hydraulic states. With its range of
where bulk ceramic, metallic and polymer protection sys-
solids are tems, Kingfisher can overcome wear problems;
conveyed, engineering suitable protection systems that
stored can add many years’ of life to a plant, and in VIGAN manufactures bulk materials handling equipment: Latest references
and proc- some cases outlast the design life of a process
essed by completely. DEKHEILA PORT
• Mobile pneumatic conveyors or vacuvators. in Egypt (Africa silos) :
mechanical, These solutions cater for the operat- • Pneumatic continuous barge unloaders and mechanical barge loaders. 2 mobile machines
pneumatic ing criteria, budget and life cycle of either with conveyors
equipment and installations that do not ben- or hydraulic means. In addition, K-BAS new equipment - particularly when initially • Mechanical and pneumatic continuous ship unloaders for vessels up to
post-Panamax. 2 x 250 tons/hour
efit from wear protection, with the one-off is a relatively inexpensive form of wear installed - or existing equipment, which can
(i.e. purchase) costs of enhanced protection, protection, which is corrosion resistance, be retrofitted with a protection system to • Mechanical loaders for any size of ships.
highlighting the continuous operational gains and offers the additional advantage of add to its current asset value. HAUTRAGE
as well as complete storage systems in ports and the agricultural industries.
of the latter investment strategy. promoting material flow. in Belgium :
The thrust of the argument is clear “K-BAS is one of the many liners we offer,” 1 pneumatic tower
when considering the typical example of an said John Connolly. “There is no one-size-fits-all From project design to complete turnkey bulk handling solutions 300 tons/hour
enclosed pipework system for conveying philosophy in respect of wear protection, that’s More inforMation:
and port terminals with reliable and cost effective equipment.
bulk materials. The system is wear protected, why we always carefully analyse all aspects of John Connolly
and so is able to provide up to 20-years of the equipment, site and surrounding environ- Managing Director
life. With this one-off approach, the system ment before we put a firm solution proposal Kingfisher Industrial
PORT SUDAN
user has little or no maintenance require- before our customer. What we are aiming Cradley Business Park
1 ship unloader
ments over the lifetime of the installation. to achieve is the longest possible operating Overend Road 600 tons/hour
He does not have the ongoing cost prob- life from an installation, to payback the initial Cradley Heath
lem – say every 4-years - of breaking the investment many times over. Our success is West Midlands B64 7DW
An affiliate company of VAN DE WIELE group.
pipework system down - and of interrupting evidenced by installations such as the one in United Kingdom
production in the process. Shropshire, which is now in its eighth year of Tel: +44 1384 410777
The long term benefits of wear protec- operation, with no problems to report.” Email: enquiries@kingfisher-industrial.co.uk VIGAN Engineering s.a. • Rue de l’Industrie, 16 • B-1400 Nivelles (Belgium)
tion as a safeguard for animal feed processing In the case of the Shropshire installation, Phone : +32 67 89 50 41 • Fax : +32 67 89 50 60 • Web : www.vigan.com • E-mail : info@vigan.com
20 | July - august 2011 Grain &feed millinG technoloGy Grain&feed millinG technoloGy July - august 2011 | 21
New VIGAN adv material for 2011 for April, August and December 2011

4. “Sticky extruded pellets and kibble
slide right out of Tapco urethane
buckets. We clean less often
now and worry a lot less about
cross-contamination. ”
Jeff Bowman
Extrusion Plant Manager
GREAT CANADIAN PET FOOD CO./
DIVISION OF SPECTRUM
FEED SERVICES, LTD.
Moorefield, Ontario, Canada
Andy Gingrich
Owner/Millwright
PROACTIVE INDUSTRIAL MAINTENANCE
Elmira, Ontario, Canada
How Tapco Helped Spectrum Feed Services
Overcome a Sticky Situation
Topical liquids used in the extrusion process of pet food After consulting with Tapco, Spectrum had Proactive Industrial
manufacturing are sticky and particularly hard to clean, especially Maintenance replace the existing buckets with FDA-compliant
when they congeal in colder weather. urethane resin CC-HD buckets. Tapco urethane buckets resist
product adhesion and flex to release caked-on build-up.
“Before changing to Tapco urethane
buckets, we’d sometimes have to “Now sticky extruded pellets and kibble slide right out of Tapco
stop production and clean twice a urethane buckets,” Bowman says. “We went from scraping buckets
day,” Jeff Bowman, Extrusion Plant twice a day, to cleaning on a weekly schedule, without concerns
Manager, Spectrum Feed Services, of cross-contamination,” Bowman says. “The cleaning process is
STYLE CC-HD Ltd. says. “That meant allocating faster and easier, too, which is important when you’re
Severe Duty Urethane Elevator Bucket
2-3 hours for two staff members to processing 140 tons a week.”
hand scrape every bucket on our 60-foot-tall legs, each time.
Need help out of a sticky situation? Talk to Tapco and
Trust me, nobody liked THAT job.”
find out why 75% of design engineers, contractors
Cross-contamination was also a constant concern and led to and bucket elevator manufacturers* trust Tapco
FANGED HEAD
more rework to maintain product quality. buckets to keep business moving. Elevator Bolt
ELEVATOR BUCKETS - ELEVATOR BOLTS
St. Louis, Missouri USA UNORMAK DEG. MAK. IML. SAN. ve TIC. LTD. Sti
Konya Organize Sanayi Bölgesi 7. Sokak No: 5/1
Tel.: +1 314 739 9191 • +1 800 AT TAPCO (+1 800 288 2726) • Fax: +1 314 739 5880 • Email: info@tapcoinc.com Konya / TÜRKIYE
www.tapcoinc.com Tel: +90 332 2391016
Fax: +90 332 2391348
*Grain Journal, Country Journal Publishing Co., Inc., Decatur, Illinois, U.S.A. © 2011 Tapco Inc.® All rights reserved. e-mail: unormak@unormak.com.tr PREVIOUS PAGE NEXT PAGE
WEB: www.unormak.com.tr

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