Stalk shredder
for big production
Models: TR-4 / TR-5 / TR-6
Before the vinification, that concludes the wine process and it is at all effects an art, an activities set must be performed probably less noble but not less indispensable.
From the harvest to the grape squeezing many of these activities can be facilitated from the machines use.
GBM that works from years in the agricultural mechanization field has studied and get ready some machines specific for the treatment of one of the main sub products of the process the grape stalk or rachis so as it is expelled from the wine pressing machines.
The grape stalks represent a reject material of the process that can be disposed in the dump or used for the composting or reused in other processes as the distillation.
In every case the grape stalks must in any way be transported in the disposing place or reused.
The grape stalk constitutes only the 5% in weight of the bunch but its structure is such as to occupy over the 80% of its volume.
When it is held in a sufficient height pile, its fibrous consistency characteristic, when the subsidence coefficient changes, it determines a density from 100 to 150 kg/m3.
On the base of these data a simple calculation allows to evaluate the problem entity:
A wine pressing process able to elaborate a bunches capacity of 50000 kg/h
• produces (50000x0.05)=2500 kg/h of grape stalks
• which increase of volume to a rate not inferior to (2500/150)=16.7 m3/h
• In 4 hours the accumulated grape stalks volume is at least (16.7x4) =66.7 m3 that can be manipulated only with a bucket if it is necessary to load it on a transportation mean.
The TR set machines are specifically designed for the grape stalks reduction through a grinding system able to bear the product density to values not inferior to 800 kg/m3.
Taking the previous example the volume produced in 4 continue functioning hours of the plant pass from 66.7m3 to only 12.5m3 with a total reduction of 81%.
The unloaded product consistency from the TR set machines is that of a fine and consistent grit which can be easily manipulated with a mechanical paddle or livened quickly from a conveyer tape.
The cutting device
All TR sets machines are supplied with an effective crumbling device constituted from two knifes set in tempered steel, one mobile and one fixed.
The knifes, of particular form, are supplied with sharpened teeth that assure a net and precise of the grape stalk constitutions.
There are 40 mobile knifes assembled with a particular sequence on a proper rotor and are kept in position from shoulder washers in tempered steel; they besides are free to oscillate on apposite centering bushings always in tempered steel.
The mobile knifes work together with con 43 fixed knifes spaced out of 25mm of size studied to optimize the cutting action and allow to generate a product extremely uniform with a size of sizes inferior to 5mm.
The rotor rotation speed is about 3500 revolutions/min, so the mobile knifes peripheral speed is very high (reaches 300km/h).
The rotor, completed of knifes is equilibrated in class 6.3.
With the aim to avoid that the irregular feeding characteristic, own of the wine pressing machines
placed upstream of the machine, determine instantaneous peaks of the requested power, the rotor is supplied with a flywheel with an inertia moment such as to assure a regular and continue functioning.
The rotor is supported from two balls double corona bearings assembled in water capacity supports.
The motion transmission from the electric motor to the rotor is realized through narrow section belts of high performances. With the aim to assure a perfect centering and alignment, the high quality steel pulleys are fixed to the respective shafts through taper-lock conical compasses.
Maximum sizes and manoeuvre spaces:
TR4 Model / TR5 Model / TR6Model
Equipment of starting electric panel and control
The supplied electric panel minimum configuration includes the following devices:
• Start and stop buttons
• Emergency button
• Ammeter
• Motor thermal-ammeterical protection circuit with intervention signaling warning light
• Start/triangle starting device
• Thermometer and temperature control of the rotor bearings
Equipment automatic devices
Automatic lubrication device of the rotor bearings constituted from automatic supplier cartridges of lithium soap grease.
Feeding conveyer tape control devices for the feeding break in case of overloading.
Optional automatic devices
Internal washing device driven with temporized electric valve; the automatic intervention device avoids the product accumulation on the internal walls and allows the machine continue functioning, for the washing device use it is necessary to make available close to the machine water with a pressure not inferior to 2 bar.
available
models and versions
TR4 machine is able to treat quantities per hour of grape stalks that suit from a minimum of 6000 kg/h (60 ql/h) to a maximum of 30000 kg/h (300qli/h).
Our TR4 machines are purposely designed to reduce stalk volume by way of a grinding system that can increase the consistency of the product to no less than 800 kg/m3.
Once the ground stalks have passed through the machine, their consistency is similar to fine, compact grit, which is easy to handle using a mechanical shovel or moved rapidly on a conveyor belt.
The picture shows the TR4 machine in basic version with direct expulsion of the grinded product. The machine conformation is such as to can throw the product in a zone with controlled access.
When it is possible to perform the free expulsion, the machine is able to treat the maximum quantity of product.
TR4 machine is characterized from a base structure.
Components
Supporting structure:
The structure is realized through cold deformation of semi worked plates obtained with laser cutting from Fe370 steel sheet metal or sheets metal in AISI304 stainless steel, having a thickness of 40/10 mm.
On the supporting structure are settled the cutting devices composed from mobile knifes and fixed ones perfectly statically and dynamically balanced.Avoiding that the dynamic stresses induced from the rotating parts generate stress concentrations that could carry to the formation of fatigue cliques, the various structure components are assembled with bolts.
The spectrum of typical frequencies generated from the cutting device during the functioning covers a range from 50 to 500Hz and this structure realization system guarantees a greater machine reliability.
The energy necessary to the grape stalks crumbling is supplied from an electric motor.Three phase asynchronous electric motors are used at two poles with external ventilation and IP55 protection degree.
The installed power changes in function of the grape stalks capacity that must be processed from the machine.
Protections
As in the case of the supporting structure all carters are produced through cold deformation of semi worked plates obtained with laser cutting from sheets metal in Fe370 steel or Aisi 304 having a thickness from 15/10 to 30/10 mm.
Always to avoid stress concentrations, all carters are fastened to the supporting structure with bolts.
TR4 machine installation
For a machine easy placing some super elevation modules in electric welded steel sheets metal are available and are provided with slits for the livening with the lifter trolley for pallets.
These modules are available with heights of 500 and 1000 mm and are stackable up to reach a maximum height of 2.5m.
The modules connection is performed with bolts. The machine with or without these super elevation modules must be fastened on ground rigidly with screws so as to prevent any movement.
The support surface must be able to support a tipping over moment of at least 5000Nm.
If the plant layout requires particular support structures, these ones must be prepared from the user under his complete responsibility.
Our TR4 machines are purposely designed to reduce stalk volume by way of a grinding system that can increase the consistency of the product to no less than 800 kg/m3.
Once the ground stalks have passed through the machine, their consistency is similar to fine, compact grit, which is easy to handle using a mechanical shovel or moved rapidly on a conveyor belt.
When it isn’t possible for planting requirements the grinded product free unload the machine can be supplied with an Archimedean screw that allows the grinded product unload on a conveyer tape, to allow the machine connection also on plants that originally don’t foresee the requirement to treat the grape stalks. The Archimedean screw can be assembled to supply both on the left both on the right.
Conduction
The TR4 machine in basic or medium version doesn’t require ordinary maintenance, in the case that is ordered with the automatic washing system it doesn’t require periodical stops for the internal cleaning.
Accidentally, when the plant works without supervision, can happen that together with the grape stalks to press some metallic parts of a certain consistency are introduced inside the machine that damage the knifes. In this case it needs to perform a stop for the knifes change with original spare parts. The operation can be easy performed following the instructions included in the use and maintenance booklet.
Our TR5 models are similar to our TR4 machines as far as performance is concerned. They are designed to avoid any interruption during the production process in the winery thanks to a bypass system. The bypass system in TR5 models has an actuator which rotates the machine by 90°, allowing the stalks to pass through the discharging screws.
The picture on the left shows the TR5 machine in basic version with direct expulsion of the grinded product. The machine conformation is so that it is possible to throw the product in a controlled access zone.
TR5 machine is characterized from a barycentric suspension structure that allows, thanks to an oleo dynamic carrier with manual or servo assistance driving, the knifes change without to stop the wine press machines.
The basic version doesn’t foresee a standard base and can be delivered complete of the rotation system that in this case must be adapted to the plant specific requirements with care and under the user direct responsibility.
The supporting structure is produced with the same materials of TR4 model and is different only in some structural elements that allow the cutting section tipping over and the protection carter rotation for the quickly change of the
knifes that eventually are damaged from metallic parts or great stones introduced accidentally with the product.
The cutting section is similar to the TR4 model one and is different only for the electric motor position that in this case is placed in a proper compartment.
Our TR5 models are similar to our TR4 machines as far as performance is concerned. They are designed to avoid any interruption during the production process in the winery thanks to a bypass system. The bypass system in TR5 models has an actuator which rotates the machine by 90°, allowing the stalks to pass through the discharging screws.
In the case of plants in which it isn’t possible or opportune the throwing unload the machine is supplied of a base with simple or double Archimedean screw in function of the wine pressing line capacity.
The unload system can be oriented on the right or on the left both in the case of medium production (simple Archimedean screw) both in the case of great production (counter rotating double Archimedean screw).
Grape-stalk shredding machine for large-scale production.
The two figures show the TR6 machine in working position with the maintenance protections and the access bridge and in bypass position with extended protections and bridge. In this configuration, reachable in a few seconds, it is possible to access in full safety to the cutting zone for the knifes change without to stop the wine press machines.
TR6 model has been settled to resolve the more difficult plant situations, for example when the space lacks physically to place the grinder machine and the only possibility is that to insert it in place of the tape that performs the grape stalks evacuation from the wine press lines.
The cutting section and the TR6 machine motor are identical to the TR5 ones but the suspension in this case is not barycenteric but on the cart.
The cart moves along tolled trimmed supported from airtight closure special combined bearings.
The cart supports also the evacuation Archimedean screws of the grinded product, the unloading unlike the models TR4 and TR5 is in line with the feeding.
Why buy a
GRAPE STALK SHREDDER
These machines are made of stainless steel; they have a electric engine with attached knives or blades that allows to shredder the stalks, and reduce the volume of the grape stalk up-to 85%.
Once processed, the stalks are moved in special containers for disposal.
Many companies also use a vacuum cleaner, which sucks the grape stalks and takes them directly to the collection points.
The stalk shredder gives a lot of advantages because it transforms the stalks, which are not considered by the current laws by-products of winemaking, in material that can be disposed of or used in other ways.
In fact, many farmers once shredder the stalks use them as fertiliser. It can also be used to produce energy.
Our machine
movable Stalk shredder
Series: TRM / TRS / TRL / TRX
A big machine in a small space .
Serie: TRB / TRP
Machines specifically designed for big production.
Serie: TR-4 / TR-5 / TR-6
GBM also offers consulting and development of special machines,custom project for satisfy any necessity.
