Vogelsang Macerator

RotaCut

Vogelsang RotaCut has cutter with integrated heavy material separator

Reliably shreds fibers and foreign matter in liquid media
Protects downstream system components from damage caused by foreign matter
Prevents blockages and clogging of pumps, fittings and pipe systems
Reduces the viscosity and homogenizes liquids and suspensions
Prevents floating layers

Product Application: Pulp & Paper, Waste Water

Product Make: Versamatic

Product Type: Grinders & Macerators

Waste water

RotaCut – reliable and effective treatment of waste water or sludge

If fibers and entanglements in waste water and sludge are causing problems, the RotaCut is the solution. With its contact-based cutting principle the cutter even reliably shreds hair and the finest fibers of (Q-Tips). Foreign matter contained in waste water or sludge is also reliably separated in the RotaCut’s integrated heavy material separator (stone catcher). In this way, the cutter protects pumps and other components in the sewage treatment plant and sewers from damage caused by foreign matter while also preventing clogging. At the same time, the sludge is homogenized, which significantly reduces the costs and effort needed for sludge thickening and sludge dewatering. Thanks to the disintegration of the sludge performed by the RotaCut, the decanter and separators run more evenly, free of disruption, to deliver superior dewatering performance. Integrated into the supply line of the digestion tower, the cutter finely shreds hair and fibers. The RotaCut therefore prevents the formation of entanglements and floating layers, while also preventing disruptions during circulation or sludge removal. Specially adapted designs and sizes are available to make integration into existing sewage treatment plants as straightforward as possible. Comprehensive features and options enable individual adjustment to the on-site situation at the respective sewage treatment plant. Thanks to the RotaCut’s user-friendly service concept, maintenance and parts replacement can be performed quickly on-site. Simply pivot out the cutter head for optimal access; wear parts can then be easily replaced by sewage treatment plant staff or by a service partner.

Industry

RotaCut – reliable cutter for industrial applications

The RotaCut, our cutter with an integrated heavy material separator, can be used in a wide range of industrial applications. This cutter offers direct contact between the blades and cutting screen, which allows it to deliver defined cutting performance, which is a major advantage for processing fibrous materials. Moreover, as the RotaCut simultaneously homogenizes the medium, it offers much more than merely pump protection for downstream systems. Medium that has been disintegrated in this manner an also be easily used in additional processes.
In industrial applications, the RotaCut is usually used together with other Vogelsang products, such as rotary lobe pumps, progressive cavity pumps or other cutters, such as the XRipper. For example, in applications involving food wastes, not all materials are suitable for being pumped onward directly after an initial shredding step. Fish, meat and vegetable waste, in particular, often contain coarse fibrous materials that are separated in a heavy material separator.
Two RotaCut models in particular have proven themselves effective in industrial applications: The RotaCut RCX is used in abattoirs as part of the RedUnit in order to meet the requirements of the EU directive on hygiene. Thanks to its compact design and reliable shredding performance, the RotaCut MXL is used on tankers to protect the pumps from foreign matter.
With features and options such as Automatic Cut Control (ACC) and Auto-Reverse function, the cutter is a key product for the shredding required in industrial applications.

Heavy material separation – Separation of stones and metal parts is important for ensuring smooth operation of the cutter itself as well as of the downstream pumps and components, and also to prevent damage and blockages they may cause. Each RotaCut therefore has an integrated heavy material separator that can be individually adjusted.
Cutting screen geometry – Vogelsang uses its proprietary software to develop cutting screens with optimized geometry for every size-reduction ratio. For operators, this means the best geometry at all times for smooth running, with minimal wear. The cutting screens are produced from wear-resistant special steel and offer twice the performance since they are reversible.
Cutting screen holder – The cutting screens are exposed to high loads in cutters like the RotaCut. This is why in the RotaCut, they are not merely supported at several points, but rather their entire surface lies on a stable holder. This reduces deformation of the cutting screen and enables easy and energy-saving cutting across the entire surface.
Cutting blades and rotors – Cutting blades and rotors have a decisive impact on the RotaCut’s cutting performance. The asymmetric blade rotors we developed in-house deliver optimal shredding performance with minimal wear. The mobile bearing of the cutting blade ensures continuous contact between the cutting screen and blade – a solid foundation for reliable cutting of even the finest fibers.
Cutting screen support – Shredding media with a high solids content in a small space places a great strain on the cutting screens. This is why we have optimized the holder on both the Pro and RCX series: the cutting screen is additionally stabilized by a central support. This minimizes deformation of the cutting screen and also enables efficient cutting despite high load operation.
Blade adjustment – Each RotaCut has a blade adjustment function that ensures that the cutting blade and screen are always in direct contact. This contact is what enables reliable shredding of even the finest, long-fiber fibrous matter, such as hair, industrial fibers and grass entanglements.
QuickService – All RotaCut products feature a maintenance and easy to maintain design. Just a few motions are required to gain access to the cutting tools, which can be replaced on-site. The RotaCut is ready for use again in no time at all. The RotaCut does not need to be removed nor the cutter head disassembled.

Automatic Cut Control (ACC) – The Automatic Cut Control (ACC) automatically adjusts the RotaCut’s blades and maintains constant pressure between the cutting screen and blade. Moreover, the pressure can be adjusted during operation; as high as necessary and as low as possible. This extends the lifetime of the cutting blades and screen, and enables automatic operation
ACCplus – ACCplus further reduces the cost of maintenance and monitoring of the cutter. It monitors the cutting blade status online and displays it on an external display. This means it’s no longer necessary to place the cutter out of service and open it to determine the cutting blade status. Additionally, this information can be processed and displayed by the (central) control and/or remote control.
Auto-Reverse function – The Auto-Reverse function detects blockages, such as those caused by coarse disruptive matter, and initiates corrective action. By periodically reversing, the function further ensures that a pair of sharp cutting edges is always used while dull ones are sharpened on the opposite site. This delivers optimal cutting performance with reduced power consumption.
Heavy material separator – For smooth operation of many biogas plants, reliable foreign matter separation of stones and metal parts is a must, in addition to shredding. The adapted design of the heavy material separator is crucial. It has to be compatible with the requirements for the respective application as well as shredding. The RotaCut offers the most comprehensive selection of heavy material separators.
Debris Removal System (DRS) – The Debris Removal System (DRS) available for the RotaCut RCX series enables regular removal of separated heavy material during ongoing operation. The system removes the heavy material with only minimal loss of medium (only around 15 l). In comparison to conventional solutions, the DRS reduces the work required by 80%
Materials – The housing of the RotaCut is made of steel and is completely galvanized. Alternatively, the exterior is painted while the interior is coated with a highly chemically-resistant epoxy resin. Stainless steel variants are available for particularly aggressive applications. Cutting screens and blades are also available in steel and/or stainless steel versions.
Cutting screens – The hole pattern of the cutting screens, along with the number of cuts, is decisive for the size-reduction ratio. To meet the requirements of every situation, we offer cutting screens for the RotaCut, depending on the size, with free passage from 4 mm to 50 mm. Stainless steel versions are available for aggressive media.