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Digital Re-print - July | August 2011

Wear protection underwrites continuity of production & supply, delivering optimum ROI in demanding animal feed market
Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872





ment and improved ROI in the animal feed processing business.

Complex and multi-layered

In 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 cleaningup 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, guaranteeing 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-

Operational factors
In common with other bulk materials handling 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 compensate for potential wear problems. Factors such as volumes, loadings, particle size and shape, viscosity and moisture content are typical criteria that must be addressed in order to eliminate potential problem 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 production uptime over longer periods all of which are critically important to improve the efficiencies of companies that operate 24/7, said John Connolly, managing director of the UK wear protection specialist, Kingfisher Industrial.

ing plant are threefold: in addition to protecting 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 materials 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 reducing upfront costs and improving ROI for the system user.

Protection from inception

If a process system 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 requirement to manufacture components using 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

he 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. This demand means that continuity of supply is all important, placing stress all along the supply chain from processing and transferring 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
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an activity where success depends on the equipment 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 hoppers, 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 creates wear problems.

Depending on the volumes and the operational 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 capability allowing production efficiency improveGrain

"Over 20 years of experience in the design, construction and supply of storage solutions, worldwide"


Silos for seeds, cereals, malts, oil seeds (soya, sunflower, rape, ...), pellets, meals, rices, and in general, products for agriculture, agrifood industry, biofuels, and biomass (wood pellets, ...) Ctra. De Arenas, km 2,300, 13210 Villarta de San Juan. Cludad Real - Espana www.symaga.com antonio.benitez@symaga.com Phone: +34 91 726 43 04/ +34 926 64 04 75 Fax: +34 91 361 15 94/ +34 926 64 02 94

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July - august 2011 | 19


In addition, involving a wear specialist such as Kingfisher at the design stage of process 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 compares the ongoing costs associated with Table 1

equipment and installations that do not benefit from wear protection, with the one-off (i.e. purchase) costs of enhanced protection, highlighting the continuous operational gains of 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 requirements over the lifetime of the installation. He does not have the ongoing cost problem say every 4-years - of breaking the pipework system down - and of interrupting production in the process. The long term benefits of wear protection as a safeguard for animal feed processing
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equipment against unplanned maintenance 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-BAS offers key benefits, such as resistance to frictioninduced abrasion and erosion in plant where bulk solids are conveyed, stored and processed 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 of promoting 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 environment 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,

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 maintenance personnel. However, Kingfisher generally 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 complete 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 they can trust.

About Kingfisher Industrial

Kingfisher Industrial provides wear solutions for process plant used to convey, process or store bulk solid materials, in either dry or hydraulic states. With its range of ceramic, metallic and polymer protection systems, 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 operating 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.

e b site ur w i sit o gan.com V vi www.

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 to post-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.
in Belgium : 1 pneumatic tower 300 tons/hour

Latest references
in Egypt (Africa silos) : 2 mobile machines with conveyors 2 x 250 tons/hour



John Connolly Managing Director Kingfisher Industrial Cradley Business Park Overend Road Cradley Heath West Midlands B64 7DW United Kingdom
Tel: +44 1384 410777 Email: enquiries@kingfisher-industrial.co.uk

1 ship unloader 600 tons/hour

An affiliate company of VAN DE WIELE group.

VIGAN Engineering s.a. Rue de lIndustrie, 16 B-1400 Nivelles (Belgium) Phone : +32 67 89 50 41 Fax : +32 67 89 50 60 Web : www.vigan.com E-mail : info@vigan.com


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July - august 2011 | 21

New VIGAN adv material for 2011 for April, August and December 2011

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

Moorefield, Ontario, Canada

Andy Gingrich Owner/Millwright


Elmira, Ontario, Canada

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, STYLE CC-HD Ltd. says. That meant allocating Severe Duty Urethane Elevator Bucket 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.

How Tapco Helped Spectrum Feed Services Overcome a Sticky Situation

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 is faster 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 FANGED HEAD buckets to keep business moving. Elevator Bolt


St. Louis, Missouri USA Tel.: +1 314 739 9191 +1 800 AT TAPCO (+1 800 288 2726) Fax: +1 314 739 5880 Email: info@tapcoinc.com

*Grain Journal, Country Journal Publishing Co., Inc., Decatur, Illinois, U.S.A. 2011 Tapco Inc. All rights reserved.

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