As environmental awareness and resulting laws have come into effect, and as managers seek to increase production efficiency, improved methods for moving debris-laden waste slurries have been needed. Historically this has been accomplished through the use of the “non-clog” pump, where a recessed or open impeller, passes large solids through the pump. However, experience has proven that the name “non-clog” does not mean the pump won’t clog. In many cases, especially where the solids size may be larger than the passages through a non-clog pump or where long stringy materials are present, a more aggressive approach, such as a chopper pump, is needed. Compared with a conventional non-clog pump, a chopper pump is essentially a non-clog pump PLUS a chopper system – that is, two machines in one.
Instead of attempting to pass whole solids through the pump, a Vaughan chopper pump cuts material into smaller, more manageable pieces as it enters the pump. Using a patented chopping action, the sharp leading edge of each impeller blade cuts material against two stationary shear bars cast into the suction plate, which extend across the entire intake opening. Depending on the number of impeller vanes, shaft rotational speed, and discharge flow, large solids are chopped into varying sizes from 3 to 30 millimeters before passing through the pump. This capability, along with its heavy-duty design and non-clog performance guarantee, set the Vaughan chopper pump apart from other types of non-clog, grinder, macerator or cutter pumps available on the market today.
If we focus on the food processing industry, the following applications are typically where the use of a Vaughan chopper pump is going to provide excellent results;
Vaughan chopper pumps are successfully being used in a wide variety of difficult applications in the meat processing and seafood industries in New Zealand and Australia. In the meat industry a chopper pump will solve difficult solids handling problems with ease. Typical applications include chopping and pumping wastewater containing paunch material, fleshings and hide, wool, blood, bone, ears and face pieces, offal and casing threads, fat and other waste materials from the processing floor.
Vaughan chopper pumps are used to chop and pump fish wastes, entrails, scales, heads, tails and carcasses, mussels and crab shells. This type of material would easily clog other types of pumps especially when other types of waste material such a plastic bags and strapping and rag enter the waste sump. A Vaughan chopper pump can chop and pump large solids such as entire fish carcasses which typically cause binding or damage to non-clog pumps.
The extensive poultry industry is finding that Vaughan chopper pumps are essential for minimising and eliminating maintenance time on processing systems which get clogged with feathers, blood, and other waste by-products. Typically, the pump would be installed in the main factory waste sump where it will chop and pump wastewater containing chicken or turkey feathers, blood, gut, legs, feet etc. In most cases, a chopper pump would normally transfer the solids laden wastewater to a rotary screen where the solids are removed.
Vaughan chopper pumps are used extensively in vegetable processing plants to transfer processing wastes. Applications include pumping wastewater containing carrots, potatoes, lettuces, apples, corn cobs and husks, pumpkin shells, beans and beet to name and few. Normally, vertical wet well or submersible type chopper pumps are used for this type of application, with a range of material options to suit depending on the fluid pH.
All of the applications discussed here center on the pump’s ability to handle solids from a pumping stand point. It is important to note that Vaughan chopper pumps can also eliminate seal and bearing failures observed in other pumps. Because the chopper design requires heavy shafting, an added benefit is longer life resulting from stronger parts and less vibration. Quite often seal failures in conventional pumps are associated with solids wrapping or binding at the impeller or seal. This can cause severe vibration that is transmitted through the shaft and seal to the lower bearing. This results not only in seal and bearing failure, but also can introduce moisture into a submersible motor. The heavier shafting and short overhang of the Vaughan chopper pump bearing and seal design addresses this problem and reduces maintenance costs as a result.
Companies in the food processing industries, and engineering firms alike are increasingly discovering the economics of applying Vaughan chopper pumps in applications in which conventional pumps have historically failed. These failures are generally due to plugging or seal and bearing failure, and all contain hidden costs that must be addressed. More often than not, equipment that has purchased solely on price has a higher failure potential than properly specified and purchased equipment. The solution starts with the user’s request to obtain equipment that will operate maintenance free, and it ends with the foresight of those with purchasing authority to think toward the future.