Horizontal grinder. Horizontal grinder

30.05.2023 Fordrejurus horizontal, гриндер

Horizontal grinder

Comparing Horizontal Grinder and Tub Grinder

Grinders are a great asset when it comes to tackling material reduction tasks. versatile than chippers and shredders, the grinders can process a wide variety of material including debris, logs, barks, construction and demolition (CD) materials, and green waste. Grinders process the big-sized materials fed into them and convert them to a refined after-product, which is often reusable.

Grinders are being utilized for a variety of applications including land clearing and preparation, tree removal, green waste recycling, bio-fuel generation, and wood mulching. They are available in a lot of different sizes and types to match the different needs of various applications. It is crucial to select the right grinder for maximizing output and ensuring safety on the jobsite.

The most common dilemma faced by anyone who is in the market to buy a new grinder is to decide between Tub grinders and Horizontal grinders. In this article, we will evaluate various parameters that will help you choose the right type of grinder for your needs. We will also talk about the benefits of electric grinders and how to know if they are a good fit for you.

How Tub grinder and Horizontal Grinder Work?

The fundamental difference between the working of a horizontal and a tub grinder lies in the way their hammermill is fed. In a tub grinder, the material is entered from a spinning, conical top-feed tub and it relies on the force of gravity to feed the hammer mill. The horizontal grinder, on the other hands, uses a chain-based feed roller and “moving floor” to feed the hammermill.

Horizontal Grinder

Both, Horizontal and tub grinders, offer unique advantages. Once you answer following questions to define your needs, you can compare both type of grinders to find the right fit:

What material will be processed by the grinder? (tree branches, pallets, CD etc.)
Do you require a specific-sized end-product?
Do you have limited space availability at your jobsites?
Does your incoming material contain contaminants like metal pieces?
How will you handle repair and maintenance of the equipment?
Does your operation require the ability to move your grinder around the jobsite?

If you have answers to the above questions, you can refer to the guide below to determine which type of grinder is most suited for you. One of our equipment specialists can help you select the right type and model for your operational needs.

Comparing Horizontal Grinder vs Tub Grinder

1.Type and Size of Incoming Material

Horizontal grinders deliver a superior performance if the input consists of longer materials like branches and tree trunks. Unlike a tub grinder which may require you to cut the lengthy materials in to smaller parts, horizontal grinder can directly be fed with such loads.

Tub grinders tend to perform better if you are dealing with bulkier materials like stumps, pallets, and root balls. The large tub infeed opening makes it easier to get the bulkier materials down to the hammermill as compared to horizontal grinders which have a narrower opening.

Both types of grinders do a good job when dealing with green waste. That said, other factors like safety considerations needs to be taken in to account before deciding.

2.Space availability and Jobsite Safety Considerations

Tub grinders can hurl out material and need more space to operate

Tub grinders can throw out materials to long distances and at considerable speed while in operation. When the material quantity gets low and the hammer mill gets exposed, it can start ejecting material out of the tub. For this reason, tub grinder needs a lot more room to operate, especially when the incoming material has contaminants like metal pieces. A tub grinder can work if your grinding operation is in a distant, controlled area where bystanders are kept at least 500 feet away.

Operators need to ensure that the tub is packed with material so that the hammer mill is always covered, and material doesn’t get hurled out. Features like the patented thrown object restrain system (TORS) found on Vermeer models, can help reduce the quantity and distance of thrown objects.

Horizontal grinders are safer and preferred in crowded areas

Due to the horizontal and more controlled feed, the hammer mill in horizontal grinders doesn’t get exposed to the material in the same way as the tub grinders. This mechanism stops the material from getting thrown to long distances and the hazard zone can often be restricted to forward and slightly outward areas from the feed opening. That said, horizontal grinders can also pose a safety hazard and should only be operated by fully trained personnel following safety protocols.

Horizontal grinders are an obvious choice if you are going to work on a space constrained and a crowded jobsite.

Ensuring safety of people and equipment while working with contaminated feed

A lot of progress has been made in the grinding equipment technology which allows for separation of metal contaminants before the material hits the hammer mill. Vermeer offers a Damage Defense system which can go a long way in reducing the possibility of damage if the mill encounters metal while grinding. Compatible with Vermeer tub grinder as well as Vermeer horizontal grinder, the Damage Defense system will alert the grinder control and automatically initiate the shutdown process. The system will reduce the likelihood of metal being pulled into the mill by reversing the feed system immediately, helping prevent significant damage to the grinder as well as improve jobsite safety.

3.Maneuverability

Horizontal grinders with tracks are easier to move around

If you need to move around the grinder at the jobsite, then you may be better off getting a horizontal grinder. Horizontal grinders, like the Vermeer HG6000TX and the HG800TX, come equipped with tracks which make them a great option if you need to reposition the grinder frequently. Most tub grinder models do not have an option of tracks so it might be challenging to use them in applications, like land clearing, where you need the grinder to be maneuverable. On the other hand, tub grinders can be a good option for stationary grinding sites if it meets your other needs as well.

4.Control Over Finished Product

Horizontal grinders offer superior particle size control

As important as the incoming product is to define your equipment needs, understanding the end use of the finished material also helps. Horizontal grinder models come with more sophisticated controls which allows them to size the output material more consistently. Also, horizontal grinders can help you achieve smaller particle size which may be a more desirable output specially for landscape mulch and animal bedding.

5.Maintenance

Simplistic design of the tub grinders makes it easier to perform certain maintenance procedures on them. Horizontal grinders, which employ a more sophisticated infeed mechanism, require a more professional approach while performing maintenance. Our experts recommend relying on certified technicians to undertake maintenance of both types of grinders to ensure higher performance, longevity, and personnel safety.

Both horizontal and tub grinders have unique features. Matching your needs against the benefits offered by each type of machine can help you select the machine that will help you maximize productivity and safety. In the recent years, the market seems to be moving towards increased adoption of horizontal grinders for factors like safety, mobility, and more control. If you are looking to replace or upgrade your tub grinder, it is worth exploring horizontal grinders available in the market and see what works the best for your operations.

Electric Grinders Benefits

Many stationary grinding operations are turning to electric-powered machines to manage cost of operation. Both tub grinders and electric grinders have electric models available in the market.

Electric Advantage

Electric-powered equipment eliminates the need for common maintenance costs associated with diesel engines, such as oil and filter replacements
Since electricity is cheaper than diesel or gas, the operating costs associated with electric horizontal grinders can be significantly lower
In comparison to diesel machines, the noise level on electric powered equipment is significantly creased, and they do not produce as much heat or emissions leading to improved work environment
Electric motors can be more reliable and require less frequent maintenance intervals

How do you know if Electric Grinder is right for you?

Before you start evaluating the electric options, use the following checklist to make sure that it would work for you operations.

Access to power source : Being powerful machines, electric grinders cannot work-off of a battery. They need a plug-in power source at the jobsite. If you currently do not have access to a 3-phase electric supply at the jobsite, then an electric grinder might not be the right option. That said, if it is possible for you to make electricity available at the jobsite, it might be worth the upgrade. In the long-run, savings offered by electric grinder would not only offset the investment but also prove to be profitable.

Material Flow at the site: If the material flow to the grinder is fixed, say from a picking line, then the electric option is a good choice for you. Portability is an advantage offered diesel grinders. Electric models may be difficult to move around since they need to be plugged-in to a power source.

Working at multiple sites: While it is possible to transport an electric grinder from one site to the other, you must ensure that there is availability of power at all the locations. If you don’t need to move your equipment from site-to-site, especially to the ones that lack electrical infrastructure, you can work with an electric grinder.

Choosing the right equipment for your grinding needs is critical for your success. Whether to select a horizontal grinder or a tub grinder, an electric option, or a diesel one depends on a lot of factors that we discussed above. Speak with one of our equipment specialists who can help you find the best grinding solution for your needs.

Selecting The Optimal Horizontal Grinder Screens

Horizontal grinder screen hole patterns come in dozens of shapes and sizes, so it’s no wonder it can be a real challenge to decide which screens you should be using.

There are several factors to consider when selecting an optimal horizontal grinder screen. The two most important ones are the type of incoming material processing and the end product being produced. The moisture content of the material being processed and its density (hardness) are the key factors to consider when selecting the shape of a screen’s hole pattern. In contrast, the desired end-product size and consistency are essential when choosing the dimensions of a screen’s pattern. The combination of the screen’s hole opening shape and size helps determine how quickly the material can be processed by the grinder and the quality/consistency of the material coming off the conveyor.

According to Jeff Bradley, product manager for Vermeer Environmental Solutions, around 95% of organic recycled material being produced today is sold as compost, mulch, and biomass/biofuel. “Each of these three different markets has different requirements for end-product sizing,” Bradley explained. “The consistency of material sizing can have a huge impact on the price a customer is willing to pay for something, especially when it comes to mulch. Many mulch manufacturers demand a consistent size and shape. Too many fines or chunky oversized material mixed into the mulch will drive down the price someone is willing to pay for it. However, product consistency requires more processing time. So, there are tradeoffs for grinding operations, and finding the right balance is what they should all be striving for.”

Grinder screen hole shape

Optimizing horizontal grinder screen configurations start with evaluating the type of incoming material and should be reevaluated when material or weather patterns change. “Grinding softer, wet material, like palm fronds or garden trimmings, has a different set of challenges than harder woods, like oak,” said Bradley. “In softer, wet material, a diamond screen works well because it creates a pitch point that can help cut the loose material. For hard, dry woods, the screens don’t play as much of a role in cutting material — only sizing. So, too much of an edge can lead to having more fines coming off the conveyor.”

Square and round holes are the two most common shapes used on grinders, but there are many other patterns to choose from. Here are a few options to consider.

Square screen: The most commonly used screen type for horizontal grinders, square holes work well in most woody materials. Square screens produce consistent material sizes, but a larger hole opening can result in varying material lengths, and regrinding or screening may be required for an optimal end product sizing.
Round screen: Commonly used on tub grinders, round-hole screens are an ideal option for working in soft to hardwoods with normal moisture levels. Round screens are more commonly used with tub grinders because they are efficient at creating consistent end product sizes.
Diamond screen: This screen is ideal for wet, difficult to grind material like compost, palm fronds, damp grass and leaves. These materials can build up on the horizontal planes of square-and round-hole screens, leading to more recirculation of material and reducing productivity. A diamond screen channels material to the point so the cutter can pinch or cut the material off and help remove material that would otherwise accumulate.
Rectangular screen: This screen allows more material to pass through compared to square- and round-hole configurations. Rectangular screens are a good overall primary grind screen. But, product consistency may suffer, so grinding and/or screening may be required.
Hex screen: This is an alternative for round screens for processing material faster since the hole design allows for more openings in the same amount of square footage (meters). The hex screen has similar production rates as square screens in many types of materials.
Snag baffle screen: A snag baffle is an option for achieving consistent end products. It’s essentially a hook on the back of the screen that snags material of the wrong specification and holds it until the knives come around again to cut the wood down to the desired size. This option provides fast processing while maintaining a consistent end product size when size requirements are the most important factor.
Grid bars: Welded horizontally across the screen face, grid bars function as a secondary anvil and are useful in a primary grind for processing construction debris or land clearing applications where there is less concern about the end-product specifications.

Grinder screen hole sizing

While the hole shape of the screen you use on the horizontal grinder has more to do with the type of incoming material being processed, the screen size is related to the end product sizing. Here is a brief overview for material sizing considerations focusing on the three big markets: compost, mulch, and biomass.

Compost: For most composting facilities, the ideal sizing is material under 4 inches (10.2 cm) in length and width. Bradley said that anything larger than 4 inches (10.2 cm) might not break down as efficiently and impact the health of the windrow’s microbiology. “Also, compost windrows with larger material will cause more wear on compost turners when turning and can result in a higher overs content in the finished compost,” he explained.

Bradley also recommended using a smaller screen size than what you think you need if you’re using a square or rectangular screen. “If a grinder operator wants 4 inches (10.2 cm) to be the maximum size and they are running square or rectangular screens, it’s a good idea to use a screen with 3-inch x 3-inch (7.6-cm x 7.6-cm) or 3.5-inch (8.9 cm) square hole sizes depending on the material. There is a bit less sizing consistency with this grinder screen configuration than with some of the other hole patterns.”

Mulch: The sweet spot for most of the mulch market is 2-1/2 inches (6.4 cm). However, there is a mulch market down to 1-1/2 inches (3.81 cm). “For mulch, having a consistent size can mean the difference between product sitting or flying off the yard,” said Bradley. “Not only do grinder operators have to make sure the material coming off the grinder’s discharge conveyor isn’t too big, but they also have to watch the number of fines too. Too many fines may require additional screening, which can eat away at a producer’s margins.”

Using a snag baffle screen is a great way to achieve sizing consistency for the mulch market. However, using this type of screen with smaller holes works best if you pre-grind the material first.

According to Bradley, many mulch producers prefer to do an initial grind of raw material using a grinder screen with larger openings, then regrind it right before selling the mulch. “The spring and fall are when the bulk of mulch is sold, and today more than 70% of mulch sold is colored. So, by having a stockpile of semi-processed material ready to regrind, mulch producers can cut down on their processing time during the busiest season and colorize the mulch right before it’s sold to maximize how long the color will last.”

Biomass/biofuel: Most of the biomass market is looking for a chip product to burn. Accomplishing this requires a chip drum and the right screens. Vermeer offers an optional chip drum for the woody biofuel market to produce a chip product. From there, you need to choose the appropriate square or rectangle screen to produce the desired chip size. The burner type, conveyor used to feed the burner, and storage arrangement drive this market’s chip sizing. Industrial burners typically are designed to handle larger biomass material sizes, while residential burners require smaller sizes.

Bradley also said there is a growing market to sell biomass material for wood pellet production. “Producing wood pellets requires extra processing by the company making the pellets, but their facilities are generally set up to work with chips in the ¼-inch (6.4 mm) range. Chip consistency and fiber length are paramount for this market.”

Mixing grinder screen sizes

Bradley also suggested that horizontal grinder owners experiment with their setup by running two different size screens on their Vermeer horizontal grinder. “For many types of wood, an operator can help improve output by running a smaller grinder screen on the bottom and larger screen on top, without much of an impact to product consistency,” he said. “The majority of product sizing is done by the first screen, so the second can be a little bigger to help purge material quickly and reduce the number of fines since the material isn’t recirculating around the mill as much. This approach can help reduce wear and maximize productivity.”

For more than six decades, Vermeer has been making an impact by providing agricultural and industrial equipment that is built tough, built to perform, built for value and backed by caring customer service. But our impact doesn’t stop there. It goes far beyond the high-quality of our yellow iron. That’s just our starting point. Today, we are an industrial.

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