F CASE STUDY

CASE STUDY

The pioneering
Hutchinson Grain Pump
systems

Grain Pumps have proven to be excellent long

life systems. The largest members in the Global
Industries Grain Pump family are the Grain
Pump Loop and Double Run Systems, which
are designed and manufactured by Hutchinson,
a Division of Global Industries, Inc., located in
Clay Center, KS-USA

n any strong family structure, each member of the

family has a unique and important role to play. These
different roles typically complement and assist each
other, and when they all work together something
very special usually happens.
Thats exactly what takes place with the Global
Industries Grain Pump conveyor family from
Hutchinson. The Grain Pump conveyors can be
used in many different ways, and operations can vary
significantly from installation to installationjust like members of
a family.
The Hutchinson Grain Pump systems were the first of their kind
in the industry, and have served grain market customers around the
world for many years. But Global Industries understands the best way
to maintain leadership in any industry is through ongoing relationships
and close interaction with customers. As a result, they continue to
work as a team with customers to not only improve existing grain
handling products but in the development of new and innovative
systems to meet ever-changing market and customer needs.
Like all Global Industries divisions, Hutchinsons customer
communications is a two-way improvement process. New systems
are first demonstrated and explained to customers. In response,
customers provide Global Industries with valuable feedback
and changes they think could make the systems better, more
cost-effective and easy to operate and maintain. Many of those
comments are then incorporated into the systems final design.
Usually, new facilities require Hutchinson to design new
members of the Grain Pump Loop system or the Grain Pump
Double Run family. But before these new systems are ever
released, they must first be thoroughly tested and evaluated
by Hutchinson engineers at Global Industries state-of-the-art
Research & Development Center in Grand Island, NE-USA.
A good example of this collaborative process is the facility
developed in conjunction with AAFSA (Agro Acopio Fertil SA) in
Durazno, Uruguay.
Originally, AAFSA planned the construction of a 1.1-millionbushel (30,000-tonne) storage facility using conventional handling
84 | April 2016 - Milling and Grain

equipment, including 23 conveyors and eight bucket elevators.

This design would have required the construction of concrete
unload tunnels below the silos, as well as connecting tunnels and
metallic catwalks to support the loading and connecting conveyors.
To reduce the overall cost of this project while enhancing
productivity, Global Industries and AAFSA worked together to
develop an alternative project based on the use of the Hutchinson
Grain Pump Loop and Grain Pump Double Run Systems. This
project design reduced the handling equipment needed to just four
10-inch Grain Pump Loops and five 10-inch Stationary Grain
Pump Double Runs (each with 150-MTh capacity).
As a result, AAFSA did not need to construct concrete tunnels
or install metallic catwalks as originally planned for this facility,
which is primarily used to clean, dry and store maize (corn), wheat,
barley, sorghum and soybeans.
The total cost of the storage and handling equipment was $1.2
million. The plant, which has been in operation since March 2008,
includes 10 MFS Model S60-16 silos with a unit capacity of 3,025
tonnes. The full perforated floor aeration systems include 30-HP
NECO centrifugal fans and 2-HP NECO roof exhausters. Each silo
includes a Hutchinson Series 1012 Sweep Auger with a 95-MTh
capacity. Both cross Grain Pump Loops were designed to allow for
expansion with additional rows of silos or flat storage buildings.
Later, a second construction phase including another 5 MFS
Model S60-17 flat bottom silos, one longitudinal Grain Pump Loop
and a second grain dryer. This was accomplished with a minimal
investment by AAFSA, and increased the overall storage capacity
to nearly 45,000 tonnes.
Since the facility launch, AAFSA has been extremely pleased
with its operating flexibility, simplicity of use and easy automation.
Another example of the effectiveness of close customer
interactions was the addition of a Grain Pump Double Run system
to load an existing flat storage building at the MYRIN facility in
Nueva Palmira, Uruguay.
The MYRIN building is 50 meters wide and 100 meters long,
and not originally designed to support the load of any conveyor.
Global Industries, together with the MYRIN management team,
developed a system to load the existing flat storage building using
a 12-inch Grain Pump Double Run with a 200-MTh capacity.
This system includes all galvanized Eclipse catwalk, specially
designed by Sentinel Building Systems, another division of Global

CASE STUDY F
Recommendations when planning a new Grain Pump
System for your facility

Industries, Inc. that is used with both the Grain Pump Loops and
the Grain Pump Double Runs
Grain Pump Loops are designed to move grain in one direction
only and in a direction that does not allow grain to flow through the
take-up corner. Electric drive corners are located on the top of the
grain pump loop. If your system only requires one drive corner, it
needs to be positioned above the take-up corner. The conveyor will
handle a wide range of free flowing grain. It should not be used
with highly corrosive material, such as fertilizers.
Grain Pump Loop Systems are usually installed around rows of
storage structures or flat storage buildings, with access for vehicle or
rail traffic. Grain silos may be conventional or elevated on a supporting
structure with hopper bottoms. It is necessary to evaluate what other
equipment may need access to the conveyor system, such as grain dryers
or grain cleaners. Systems have been used to transfer between trucks and
rail cars with several temporary storage silos included. A layout should
be made to determine the exact location of conveyors, inlets, outlets,
power sources, supports and mounting locations.
In order to select the right Grain Pump Conveyor System for your
application, it is important to analyze the following:
Determine the adequate volume flow rate to support the intended
input and output. The systems are rated in Bushel per Hour/ Tons
per hour capacity.
Calculate the expected annual operating hours usage: Total
Storage Volume x Storage Turns Rated Capacity of Loop.
Consider the material to convey, and its abrasive characteristics
as this may be the determining factor for Usage Classification:

Standard Farm

Standard Farm with upgrades: (Standard Farm model with tubing

thickness upgrades)

Commercial

Commercial with upgrades (12 and 16 loops)

Tubing thickness upgrade on 12
The 16 is standard with highest classification
Usage classifications are a suggestion only, and even though an
application may only call for a standard duty Grain Pump based
on the hours of operation, it may be desirable to use a Commercial
Grain Pump for other reasons.
www.globalindinc.com

Operating Hours Chart - for considering the Grain Pump System Model
Usage Classification*
Standard Farm
Standard Farm with upgrades
Commercial
Commercial with upgrades

Annual Operating Hours

0 - 250
250- 500
500 - 750
750 and greater

* Classification is dependent on operating conditions and practices

1. Is there room for a row of silos plus the possibility of expansion?

Consider your operating plan, location of controls, power
distribution, driveway, and turn around areas.
2. If planning a flat storage building, assure the building is capable
of supporting the Full load of the Grain Pump System, grain, and
catwalk (this load is in addition to your regional roof load).
3. Can spouts be run to an adjoining storage area if desired?
4. If there is a dryer involved, consider separate conveyors from the
wet holding to the dryer and from the dryer to storage. This enables
the Grain Pump to be always free for grain from the field and keeps
the low capacity, long continuous hours of use on less expensive
conveyors.
5. Consider two drive-over dump receiving hoppers for grain pump
systems that will have many trucks or wagons dumping grain. This
will result in more continuous operation which can almost double
capacity.
6. If larger/wider drive-over pits are desired consider the following:
a. The wider the inlet is for the drive-over pits, the deeper or taller
it will need to be to maintain angle of flow in the hopper. The
options are to lower the tube or raise the driveway.
b. To lower the tubes, spouts will have to be added to the inlets for
the intermediate wells, and the loop will have either a deeper
trench or higher elevated silos.
c. If the drive is raised, carefully consider the ramp grade, load
design, side personnel access, safety rails, and overhead clearance.
7. A grain pump loop must have a climbable tower at each end and
access to every overhead drop. Catwalk can be considered for
the full length, but it is generally not necessary if every silo has a
ladder extending to the overhead drop area. When catwalk is not
used full length, some catwalk may be needed to reach the drop
over the driveway.
8. Every component of a grain pump loop system should end
up located above grade to avoid water issues that can rust the
conveyors housing and chain. If located below ground level in
a trench or pit, adequate drainage to daylight or sump pump is
required. Assure landscaping diverts drainage away from pit; covers
should be used over any open areas to shed water.
9. When choosing a system size, consider capacity required now
as well as into the future. These units will handle a lot of grain
before major parts replacement is necessary. The loop is modular,
as length can be added in the future up to the maximum designed
length for the particular system.
10. Plan for enough space between silo foundations to allow space for
silo well controls (this is outside space between silos). Concrete
foundations, trenches and floors need to have maintenance access and
clearances considered in the design layout. Refer to the equipment/
component specifications to plan adequate space and clearances.
11. If concrete is placed before the system arrives, the corner support
pads should be lower than the bottom of the horizontal tubular
housing; there are support feet on the bottom corners (refer to the
equipment specifications). Again, if concrete trenches or pits are
utilized, assure maintenance access is adequate.
12. Make sure there is suitable electrical power available. Single phase
power may be used if HP requirements allow.
13. Make sure amp meters are used so motor loads can be observed by
the operator. Soft start electrical motor starters are recommended.
14. Chain inspection ports are recommended. Utilize one inspection
port between the drive-over pit and the first loop corner to monitor
physical tube fill. Utilize ports after each silo if possible. Ports are
for horizontal tubes only.
15. Chain access section kits are available for use on the horizontal
tubes only.
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