Rendering Update

BIG NEWS!

New SuperPressor® Doubles Throughput

The new Dupps SuperPressor

Just over two years ago, Dupps surveyed each of our customers about what they wanted in a screwpress. The response was good, and one request stood out:

More throughput!

Now it's our turn to respond by introducing the new Dupps SuperPressor. Extensive field testing has demonstrated at least double the throughput of the original Pressor® with no sacrifice of residual levels.

Of course, we kept all those features that have made the Pressor® the world leader in rendering - integral gearbox, direct coupled motor, hydraulic choke and extra rugged frame construction.

Greater productivity just got easier. See your Dupps representative for details.

Like New Pressors!

Ever wish you had a brand-new Pressor®, but not have the budget? Then check out our new factory remanufacturing program.

When we receive your tired, old press at our factory, we'll first completely disassemble it. Then we'll sandblast all structural parts are re-machine them to original specifications. We'll check moving parts closely and replace them if they're worn below standards. And we'll replace all bearings, seals and thrust bearings. The result is a like-new Pressor®, at a fraction of the new machine cost.

This is just one part of our complete rebuilding program. Check with your Dupps representative for more information on rebuilding any of your Dupps equipment at your place or ours!

Maintenance Tips

Equacooker® and Supercooker® shaft journals can sometimes become grooved and fall beneath proper dimensions when a bearing or seal fails. This prevents the bearing from functioning properly and can ultimately lead to major shaft damage.

Dupps now offers in-place machining and sleeving of worn journals to bring them back to original specifications. This repair could save you a major breakdown.

Another potential problem area is the parking sleeve. When worn 1/8", it should be replaced to avoid serious shaft damage. This can be done either by your maintenance staff or Dupps field service.

Archived Update Stories (in html):

ICIS® Automated Process Control
Offers Information And Maintenance Advantages

Pressor® Maintenance Tip Number 1

Pressor® Maintenance Tip Number 2

Dupps Introduces New
Bi-metallic Cast Flights

Major Producer Expands Pork Rendering
Capacity With Dupps Retrofit Evaporator

Dupps Announces Pressor Improvements

New Cooker Inspection Program
Designed To Extend Vessel Life

New continuous hydrolyzor installed

Retrofit benefits

DAF evaporation system available for on-site demo

Short notes

ICIS® Automated Process Control Offers Information And Maintenance Advantages

The ICIS® (Integrated Control and Information System) uses a Programmable Logic Controller for complete process control. The operator interface consists of a desk and pre-programmed, simple-to-use personal computers with animated process graphics.

The ICIS system monitors and controls temperature, product level, weight, speed, pressure, flow rate, and motor load. It also gathers real-time data for monitoring the process and stores it for later management analysis, providing information on virtually every operating parameter that affects quality, throughput and efficiency. In addition to collecting data, the system's Data Acquisition Package summarizes each run in terms of the plant's run time, steam used for cooking, vapor condensate produced, pounds of steam per pound of water evaporated, fat produced, and crax produced.

Should one of the personal computers fail, the other ones can run the entire plant. Dupps will supply a list of recommended PLC spares for you to buy or have your local distributor stock in case of PLC board failure.

Maintenance Software Package

The ICIS system also offers an optional Maintenance Software Package, a multifeatured program that helps you maintain your plant's equipment. This software package provides an hour meter for each piece of equipment connected to the PLC. The manager inputs recommended service intervals into the package, which then automatically flags him when maintenance is due for each system component. The package also includes space for recording the work required at the recommended service interval, space for recording maintenance history, and a spare parts list and easy order form.

On-Line Troubleshooting

If problems with the ICIS ever arise, Dupps engineers in Germantown can troubleshoot the PLC in a timely and cost-effective way via an on-line modem hookup. They will literally monitor the process over the phone with-out the delay and cost of travel to your plant.

Other ICIS features include its flexibility/ expandability which al-lows for the addition of whole new processes to the plant, and the capability to hook up a remote off-site computer via a modem connection over telephone lines.

The Dupps Company also includes hands-on instruction on ICIS basics during and immediately after installation. This allows your workers to become quickly acclimated to ICIS. To learn more about ICIS, call Brent Brown at 937/855-6555.

Maintenance Tip Number 1

Threaded Inserts For Pressor® End Plates

Looking for a way to replace your stripped Pressor end plate threads?

The Dupps Company has developed a process that lets you replace the old threads with inserts. Dupps now offers a field retrofitting service that places threaded inserts in the press end plate.

A Dupps service crew will come to your plant to drill out the old threads and weld in the inserts. This allows easy replacement if you ever need new threads again in the future. This service will work even if your screw press is something other than a Dupps Pressor.

For more information contact Dave Cadic at 937/855-6555.

Maintenance Tip Number 2

Pressor Cage Maintenance

Broken barrel bars are often the result of bent or bowed cage ribs. Before relining your cages, always check the ribs by laying a straight edge the full length of the cage to see that all ribs are touching the straight edge. If you notice a gap of 1/16" or more, the cages may be due for rebuild.

The Dupps Co. offers a cage rebuild service to bring the ribs back to specifications. If you have any questions, check with our route drivers or parts department at 937/855-6555.

Supercookor® Journal Sleeve Maintenance

To extend the life of your shaft journal sleeves, repack the stuffing boxes with new packing (in accordance with the packing manufacturer's instructions) at least three times a year.

To get working clearance for repacking the stuffing box, remove the flinger ring (if there is one) next to the bearing. Also remove the packing gland. The flinger and the gland are both split so you can remove them without disturbing the shaft or its bearings.

The journals (the portions of the shaft that rub against the packing) are covered by replaceable wear sleeves. Sleeve replacement provides a new sealing surface with-out the need to machine the shaft journal. When repacking the stuffing box, inspect the wear sleeve. If it has worn more than 1/4 inch on the diameter since new, or if the sleeve is in poor condition, the packing won't seal properly, so you'll have to replace the sleeve. New replacement wear sleeves come with installation instructions.

Before repacking the stuffing boxes or inspecting the journal sleeve, be sure the cooker is empty and the internal pressure is zero before removing either agitator shaft packing gland. Failure to do this could result in serious personal injury.

For more information on journal sleeve replacement and repacking stuffing boxes, contact the Dupps service parts department at 937/855-6555.

End of newest Dupps Update. Archived stories below.

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Dupps Introduces New
Bi-metallic Cast Flights

Patented Casting Process
Increases Shaft Life By 50%

The Dupps Company has announced the introduction of a revolutionary line of tough new flights that can increase Pressor® shaft life 50% beyond any other flight on the market.

This innovative flight design is made possible by a patented bi-metallic manufacturing process that delivers breakthrough shaft longevity and performance.

Traditional flight manufacturing processes weld wear-resistant material to the body of the flight. The unique Dupps high technology procedure casts a hard, wear resistant surface over a softer core. This casting method yields flights which require very little break-in time, thanks to their superior surface finish and precision dimensionality.

They also offer unparalleled service life because of the exceptional wear properties intrinsic to their cast outer surface; casting produces an inherently more homogeneous structure with few defects.

Despite these new flights' greater strength and durability, The Dupps Company is offering them at no price increase over our conventional flights.

For more information on product specifics and pricing, call The Dupps Company at 937/855-6555.

Learn More About Tuffcast(tm) Flights Here!

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Major Producer Expands
Pork Rendering Capacity
With Dupps Retrofit Evaporator

One of America's largest meat packing and processing companies is also a world leader in the production of pork co-products for rendering. This well known company, which prefers to remain anonymous, is a long-time Dupps customer.

In the late 1970's they planned for the future by installing a Dupps 1800 Equacookor system. They stayed ahead of the curve six years ago by updating their system with a Dupps Supershaft, allowing them to process approximately 28,000 lbs. of raw material per hour.

Recently the company wanted to increase their kill, so they explored ways to expand their rendering capacity to support the additional slaughter.

The first option they considered was a bigger cooker. This presented a problem because it would require additional steam, and they were already at the limit of their existing steam plant. They'd have to buy and operate a new boiler system - expensive even if they had room for it... which they didn't.

Their second (and best) option was a Dupps retrofit evaporator system. Company engineers knew this would cost more than a larger cooker, but calculations quickly proved that eliminating the need for a new steam plant more than offset the retrofit system's cost.

Other benefits clinched the decision. Because it uses waste heat from the cooker, a Dupps retrofit system increases thermal efficiency. It also solves the condenser problem: the heat recovery condenser now makes hot water for use in scalding and clean-up operations.

And, of course, the new rendering capacity - operating for almost a year now at about 45,000 lbs./hr. - positions them for considerable growth.

Dupps worked with the packing company's engineers to install a retrofit system built around a forced circulation flash evaporator, the preferred choice for applications where tube coating is a problem. The main components are a horizontal shell and tube heat exchanger, a flash chamber mounted above the heat exchanger, and a circulating pump.

Fat and water circulate through the heat exchanger tubes at high velocity to inhibit coating and enhance heat transfer. Liquid from the heat exchanger enters the flash chamber where water is flashed off. Since there is no coating in the heat exchanger, evaporator performance remains constant without expensive cleaning procedures.

The company eliminates the downtime to clean heat exchanger tubes, plus the cost of cleaning. Even better, they saved more up front because they didn't have to oversize the evaporator to compensate for coating build-up.

The Dupps Company invites you to send for an annotated Retrofit Protein Recycling Evaporator System schematic that shows and explains each step in the system.

Phone 937/855-6555;

Fax 937/855-6554

E-mail info1@dupps.com

Or write:

The Dupps Company
P.O. Box 189
Germantown, Ohio
45327-0189

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Dupps Announces
Pressor® Improvements

New Pressors now come with pipe rails
where you can hang the splash shield.

This allows you to observe cage drainage
without exposing the whole side.

Also...

The new standard feed chute into the hopper from a conveyor has a special grating designed to let you see what's coming down the chute while preventing access to moving parts of the Pressor®.

A new design for quick-opening inspection doors replaces the quick opening handle with a hex nut that can't be spun off or kicked off. Opening the door, while still fast and easy, now requires a socket wrench.

The Dupps Company is engaged in a continual process of design refinement for ongoing product improvements to enhance performance and safety. For this reason, all published specifications, drawings and descriptions are subject to change without notice. Please contact The Dupps Company for the latest facts and figures.

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New Cooker Inspection Program
Designed To Extend Vessel Life

Dupps recommends an annual inspection and evaluation of all batch cookers, Equacookors® and Supercookors®. Process materials gradually wear down the tube walls, stiffeners and inner shell, and wash away weld metal. This eventually reduces the vessel's operating pressure rating and structural integrity.

We now offer our customers regularly scheduled inspections and a recorded wear history. The goal of this new program is to prevent costly unscheduled downtime due to a failure, and help satisfy OSHA 1910.119 requirements for the mechanical integrity of pressure vessels.

For those who take advantage of this program, we will provide the following:

1. Nondestructive ultrasonic measurement of cooker shaft and shell wall thickness.
   
2. Visual inspection for cracks, gouges, unusual wear, and the condition of structural welds.
   
3. Analysis by the Dupps Engineering department as to the maximum allowable operating pressure rating of the vessel.
   
4. A written report of our findings, detailing the vessel's fitness for service; current operating pressure rating; recommended repairs, if any; and the recommended time interval before the next scheduled inspection. This report will include copies of supporting test data sheets.
   
5. Timely notification when the next scheduled inspection is due.
   
6. A record of each vessel's inspection history kept on file at The Dupps Company.

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Continuous Hydrolyzor®
up & running at
25,000 pounds/hour

The Dupps Company has designed, manufactured and installed the newest Dupps Continuous Hydrolyzor design for Central Bi-Products in Redwood Falls, Minnesota.

Operating on 65% turkey and 35% broiler feathers, the unit started up and met capacity within one week.

All product contact parts are constructed of 304 stainless steel. Carbon steel is also available.

The feeder, vessel design and control system are all unique to the Dupps unit.

The Dupps Continuous Hydrolyzor is the protein recycling industry's best choice for consistent high quality products on a continuous basis.

Reliability-proven screw feeder technology provides a positive seal for the hydrolyzing vessel, and a steam heated agitator shaft ensures optimum heat transfer and steam efficiency

Valve-controlled product discharge maintains product residence time and minimizes steam use. An advanced Programmable Logic Controller provides maximum control.

We are proud to have exceeded our customer's requirements in both process control and product quality.

Central Bi-Products has kindly allowed us to show this unit, and we welcome requests. Call 937-855-6555 or fax 937-855-6554.

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Retrofit Benefits

You can automate the batch hydrolizing of feathers by having Dupps add a Programmable Logic Controller, steam control hardware, and a special by-pass unit to your existing system.

Benefits include greater product consistency, more throughput, and less labor.

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Dupps offering on-site
demonstration of new pilot
DAF evaporation system

Now you can "test drive" a new Dupps evaporation system.

You simply schedule a visit from the pilot version of a unique Dupps Dissolved Air Flotation evaporation system - designed to remove moisture from DAF sludge and separate the dried product into streams of fat and solids.

The pilot not only demonstrates its ability to handle your facility's DAF stream, but also collects data that allows the design of an evaporation system to meet your specific needs.

Simulating both single effect and multiple effect systems, the Dupps pilot version will convert DAF sludges containing 80%-90% water into dried product streams. The separated fat from the process is completely recyclable and the dried solids may be easily mixed with any meal.

Arrange a demonstration of the exclusive Dupps DAF Evaporation System at your plant. Phone 937-855-6555 or fax 937-855-6554.

 

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Short Notes

New hydraulic gantries now provide The Dupps Company's fabrication department with lifting capacities of up to 400 tons. This latest enhancement of our production capability will help us continue to give our customers the industry's best products and service.

Dupps cast screw press flights now give you the longest wear life ever offered to the industry - - but at no increase in cost! You can learn more by calling 937-855-6555 or faxing 937-855-6554.

Dupps Supercookor® model 440U - based on the time-tested Equacookor® design, but offering more heat transfer surface - features evaporation rates up to 35,000 pounds per hour.

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