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Muffin Monster inline/open channel grinders

For problem sewers or issues with pump blockages, the Muffin Monster is the best solution. The sewer grinder handles wipes and rags to reduce pump maintenance and avoid clogged sewers. It acts as a shredder, grinding debris into particles small enough for all pumps to handle effectively, allowing pumps to function at maximum efficiency. The grinder is available in three different models each with two different configurations.

  • Protect pumps and other critical equipment from costly clogs and damage from tough solids
  • Wipes Ready cutters prevent materials from forming long strips and reweaving in the waste stream
  • No labor needed to clean, disassemble and reassemble the repair unit, or wait months for parts. Just swap and go!
  • Delta P side rails ensure solids are processed by the dual-shafted grinder while optimizing flow through the unit
  • Lower operating costs by keeping pumps and other equipment running efficiently
  • Sewage pump stations
  • Headworks – primary treatment
  • Sludge processing
  • Anaerobic digestion / Bioresource
  • Septage / Grease receiving
  • Correctional facilities
  • Airports
  • Facilities management
  • Dual-shafted, high-torque grinders handle rags, rocks, woods, wipes, clothing, plastics and other debris
  • Wipes Ready cutters create two-dimensional cutting capabilities to control width and length of output
  • In-line 30K Muffin Monster includes an easy-to-remove cutter cartridge
  • Patented Delta P side rails drive debris into the cutters
  • Grinders reduce solids to a size that pumps and other equipment can process efficiently and safely
  • Housings: ductile iron
  • Cutters: hardened alloy steel
  • Shafts: hardened alloy steel
  • Mechanical seals: tungsten carbide faces

The 10K Series Muffin Monster is a compact grinder, tough on solids in sludge and sewage applications. It fits into areas with limited space, while still providing the necessary power for downstream protection. The 10K Series is an ideal, low-cost solution that goes beyond sludge grinding at resource recovery facilities. It fits perfectly into office buildings, apartment complexes, resorts, retail centers and package treatment plants.

  • Hex shafts: 50 mm
  • Motor: Standard 1.5 kW; 25:1 reducer
  • Cutter size: 120 mm diameter
  • Seal max working pressure: 6 bar (optional severe-duty seals available)

Open channel model

Troublesome solids are now easier than ever to reduce with the Muffin Monster dual-shafted grinder. Its slow-speed, high-torque design shreds tough solids that typically cause sewer problems. The 30K Muffin Monster is available as both inline and open channel configurations.

  • Hex shafts: 50 mm
  • Motor: Standard 2.2 kW; 25:1 reducer
  • Cutter size: 120 mm diameter
  • Seal max dry working pressure: 10.3 bar

Open channel model

The 40K Series Muffin Monster excels in wet and dry grinding applications. It is a powerful shredder for large processing systems. It also serves in many industrial applications, including fish and beef processing, petroleum, pulp and paper mills, chemical plants, and recycling plants.

  • Hex shafts: 64 mm
  • Motor: Standard 7.5 kW; 35:1 reducer
  • Cutter size: 191 mm diameter
  • Seal max dry working pressure: 10.3 bar

Open channel model

Cutters

  • 7,11,13 and 17 tooth options Wipes Ready serrated cutters
  • Cutter stack can be tailored to meet operational requirements
  • Available in optional stainless steel for 7, 11 and 13 tooth cutters

Motors

  • IP55 TEFC Motor, standard
  • IP55 TEFC Motor for ATEX: (Ex d IIC T4), optional
  • IP68 Immersible Motor ATEX: (Ex de IIB T4), optional
  • IP55 Integrated drive, 10K only
  • Extended drive shafts available

Smart controller

  • Load-sensing control system automatically reverses to clear jams
  • Powder-coated mild steel or stainless steel IP65 enclosures

Custom frames

Wipes Ready Technology

Muffin Monster sewage grinders are available with the unique, Wipes Ready technology. It is designed to capture all wipes in the waste stream and shred them into small pieces that will not reweave to form ropes and ragballs in sewage systems.

The Wipes Ready technology applied in Muffin Monster sewage grinders includes:

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  • Wipes Ready cutters – A combination of serrated cutters and knurled spacers cuts wipes in two directions. The result is smaller particles that cannot reweave downstream.
  • Delta P side rails – Direct solids into the cutters without sacrificing flow rate and prevent debris build-up in the grinder
  • Optimized cut control (OCC) – The OCC gear ratio optimizes shaft speeds to enhance the cutting action and cleaning of the cutters, which in turn improves the performance and life of the grinder.

Please note that different Muffin Monster models feature different Wipes Ready options.

Textiles and other unconventional debris can be a tough problem for pumped wastewater systems. That’s why more and more operators are addressing the problem at source with Sulzer’s Muffin Monster grinder technology.

A Sulzer Channel Monster has been a lifeline for a large-scale wastewater treatment project in Vác, Hungary

Drivers rely on motorway rest areas and service facilities to ensure their comfort and safety on long journeys. However, for Austrian operator ASFiNAG, heavy use of these facilities was leading to maintenance headaches. Now, thanks to Sulzer’s Muffin Monster grinder and Piranha pump technology, wastewater pump blockages are becoming a thing of the past.

Municipal utility company Servicebetrieb ASK in Nordrhein-Westfalen was experiencing frequent blockages and outages in one of its sewage pumping systems. The main cause was the proportion of solids in the wastewater. Sulzer recommended the upstream installation of a dual-shafted grinder, known as the Muffin Monster and since its installation, the sewage pumps have been operating perfectly.

Blocked wastewater systems are a perennial challenge for hospitals around the world. To keep these critical systems running, leading healthcare facilities are turning to Sulzer Muffin Monster grinders as an effective first line of defense.

Large wastewater treatment facilities often incorporate an anaerobic digestion (AD) plant to handle sludge and deliver heat as well as electrical energy to support the operation of the site. Process performance depends on equipment reliability and getting the most out of the feedstock. Improved efficiency enables plants to increase throughput without expanding the site and this can be achieved by optimizing the sludge handling equipment.

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Villa Mountain Vista North in Las Vegas installed a 30K Muffin Monster to get rid of clogging in their onsite lift station.

Learn how the powerful 30K Muffin Monster greatly reduces material clogging and downtime at a biogas facility in Catalonia, Spain.

Port-a-Loo, New Zealand’s largest septage hauler, invested in a 40K Muffin Monster to eliminate frequent clogging of wastewater pumps at the disposal site.

Learn how the 10K Muffin Monsters help Schertz water reclamation plant in Texas, USA, grind the toughest solids more reliably with less energy.

Sewage system operators deal with problematic waste such as wet wipes, disposable wipes and other solids flushed down toilets. They spend a lot of resources cleaning their pumps of unwanted solids in the sewage. Our Muffin Monster range, very powerful grinders, break these solids down and prevent pumps from clogging.

Wherever fluids are pumped, mixed, controlled or applied, we are there. See how our solutions create value for customers and learn how we can make your pumping and mixing processes more efficient and profitable, safeguarding your production and ensuring lasting reliability.

Manual

Anaerobic digestion requires temperature equalization and proper homogenization of the biomass to achieve a high gas production and to avoid sedimentation of organic matters. The surface crusts must be broken and prevention of foam must be managed if there are foaming tendencies. Sulzer can provide efficient and reliable Scaba agitators for digesters with high-efficiency propellers. Muffin Monster grinders upstream from the anaerobic digesters condition the sludge before digestion, improving the homogenization of the biomass and protecting the equipment downstream.

Commercial wastewater from toilets comprises all sewage water flushed from toilets on commercial, industrial or public properties.

Network pumping stations collect municipal wastewater from residential homes and communal schemes. Installed in dry or wet wells, the pumps deliver the effluent to a terminal pumping station. Since most pumping stations are not equipped with screens, the pumps must cope with difficult materials such as fibrous sanitary and packaging items.

The sludge buffer tank can be used for a variety of purposes. The most common application is the blending and homogenization of highly concentrated primary, secondary or digested sludge. The solution used to mix the sludge itself, or to mix the sludge with the dosed thickening chemicals, depends on the design and volume of the sludge buffer tank. Submersible mixer types ABS XRW and RW, as well as the agitator type Scaba, can be used to provide highly efficient mixing. Positive displacement, progressing cavity transfer pumps and Muffin Monster grinders are used for solids reduction and sludge transfer from sludge feed to sludge dewatering process.

Sulzer pumps, mixers, grinders and agitators are used to condition, transfer, blend and handle sludge. Our progressing cavity, positive displacement pump range, provide a near constant flow rate with suction lift capability, for handling all types of non-Newtonian sludge and cake processes, typically demanded within the wastewater treatment plant. Maintain in place features ensure any process downtime due to the change out of wear components is kept to a minimum. The Muffin Monster grinders protect the equipment downstream. The sludge conditioned by grinders will not clog valves, heat exchangers, digesters, centrifuges and other equipment on the sludge line.

Terminal pumping stations receive municipal wastewater from network pumping stations. Installed in dry or wet wells, the pumps forward the medium to a treatment plant for final purification. Due to the lack of screens at most pumping stations, difficult materials such as fibrous sanitary and packaging items are a constant threat to uptime.

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THE FRONIUS TIG WELDING SYSTEM THAT MAKES NO COMPROMISES

PRECISE. DURABLE. INTUITIVE. WITH THE iWAVE SERIES, NOT ONLY CAN YOU SMASH EVERYDAY WELDING TASKS; YOU CAN ALSO UNLEASH YOUR WELDING POTENTIAL AND MAKE YOURSELF FUTURE-PROOF. FLEXIBLE.

Video: Full freedom. to unleash your welding potential

Top quality – for every weld and every material: with its targeted heat input and improved ignition function, iWave gives you maximum control over your arc while significantly reducing ignition delays.

All the operating controls on the iWave series have likewise been designed for maximum control. This makes the systems intuitive to use, leaving you free to concentrate solely on the challenges of your welding task.

Need a system that can master the full array of welding challenges? If so, iWave Multiprocess PRO is the perfect choice: in addition to offering every imaginable TIG function, it also accommodates all MIG/MAG welding process variants.

iWave highlights

TARGETED HEAT INPUT

MAXIMUM CONTROL OVER THE WELD POOL

CycleTIG allows you to control the arc, in turn giving you maximum control over heat input. The short welding times make it easy to keep a safe handle on the weld pool. As a result, you can weld even the thinnest of materials with ease.

INTUITIVE OPERATION

DYNAMIC GRAPHICS-BASED MENU NAVIGATION – IN OVER 30 LANGUAGES

No additional documentation. No wild goose chases. Just follow your instincts. Our intuitive menu navigation concept eliminates unnecessary detours during welding, allowing you to make the required settings with confidence.

MULTIPROCESS PRO

ONE SYSTEM FOR ALL PROCESSES (iWave 300i–500i)

iWave and Multiprocess PRO – your key to unbridled welding freedom. Along with every possible TIG function, all MIG/MAG welding process variants are accommodated within a single system. Benefit from the modular concept that allows you to expand your high-tech welding system platform according to your exact needs. Simply choose from the following Welding Packages: Standard, Pulse, PMC, or LSC and CMT.

REPRODUCIBLE IGNITION PROCESSES

IGNITION DELAYS REDUCED BY UP TO 71%

Ignition processes that are fast and – perhaps even more importantly – reproducible. Regardless of the material characteristics and without having to adjust any ignition parameters manually. That’s what you get when you opt for RPI auto – our intelligent ignition function.

Compared to RPI off | Test series conducted under laboratory conditions: 200 A welding current / 0.5 s welding time / 1,000 ignitions!

INDUSTRY 4.0 READY

CONTACTLESS DATA TRANSFER AND AUTHENTICATION

Ready for Industry 4.0 and anything else that comes its way: from WLAN and Bluetooth right through to NFC, iWave supports all the major connection standards so that you can put it to the best possible use.

The iWave welding system variants at a glance

Connectivity (WLAN, Bluetooth, NFC) as std.

Multiprocess PRO iWave 300i-500i

One welding system for all welding processes (TIG – incl. HF – and MIG/MAG right through to WP CMT, MMA, and CEL) with no compromises on quality.

TIG iWave 190i-500i

The intelligent TIG welding system for industrial applications and outstanding quality whatever the materials involved.

  • iWave DC: 230i/300i/400i/500i
  • iWave AC/DC: 190i/230i/300i/400i/500i

MAXIMUM MODULARITY WITH THE iWAVE TIG WELDING SYSTEM Adaptable and expandable based on a modular approach: thanks to the standardized interfaces, you can mold iWave perfectly to meet your requirements. Customization not only encompasses system configuration but also the range of functions on the welding system and is even possible at a later date.

One hosepack for any application.

Flexible transport units for mobile use.

Alongside the many other options, you might – for example – be interested in the CycleTIG function for easier TIG welding.

The heart of the iWave welding system. DC or AC/DC, 190-500 A, Standard or Multivoltage (MV), etc.

Optimum cooling capacity with optional water cooling.

Thanks to Bluetooth, NFC, and WLAN connectivity, the iWave supports contactless connection – e.g., to the RC Pedal for remote control.

WeldCube for local or central data documentation.

From personal protective equipment to electrode grinding machines – we can offer you a comprehensive range of accessories.

One hosepack for any application.

Flexible transport units for mobile use.

Alongside the many other options, you might – for example – be interested in the CycleTIG function for easier TIG welding.

The heart of the iWave welding system. DC or AC/DC, 190-500 A, Standard or Multivoltage (MV), etc.

Optimum cooling capacity with optional water cooling.

Thanks to Bluetooth, NFC, and WLAN connectivity, the iWave supports contactless connection – e.g., to the RC Pedal for remote control.

WeldCube for local or central data documentation.

From personal protective equipment to electrode grinding machines – we can offer you a comprehensive range of accessories.

Improved control

A safe bet for improved results

Made by welders for welders: all the operating controls on the iWave series have been designed with your daily tasks in mind – in terms of their sturdiness, colors, legibility, and brightness. That also goes for the settings, as all the key work parameters are directly available on the very first menu level. The plain text display supports over 30 languages for maximum intelligibility. Not only that, but operation while wearing gloves has never been easier.

iWave 300i-500i

Plain text display in over 30 languages gets you to the relevant setting as quickly as possible

Intuitive and reliable: the system is operated using the central press-and-turn button or via the touchscreen. Users receive direct support in the form of graphic-based instructions and dynamic visualizations when making changes to parameters.

Dynamic graphics-based operating concept

  • Immediate graphic feedback whenever various welding parameters are changed
  • 7″ color plain-text display and touchscreen
  • than 30 language options
  • All work parameters located on 1st menu level
  • Status display: configured additional functions and main settings at a glance
  • 5 EasyJobs
  • Touchscreen can even be operated while wearing gloves
  • Full-screen mode: increases display size by around 40%
  • Configurable 1st menu level

Straightforward. Clear. Structured.

The iWave operating controls

Status bar Configured main settings and additional functions at a glance (e.g., welding process, operating mode, polarity, HF).

The 7″ color display is even easy to operate while wearing welding gloves.

In this mode, the display size is increased by 40% and only the main work parameters are shown. This ensures clarity and means that the display can also be read easily from a distance.

With this function, you can save all the parameters for recurring welding tasks, and retrieve them quickly and easily whenever you need them.

Wire threading The welding wire is fed automatically through the hosepack and welding torch at the touch of a button without having to open the feed rollers. None of the shielding gas escapes during this process.

Gas test If it has not been used for a while, the hosepack can be flushed with shielding gas by pressing the gas test button. That way, the gas shield is already in place when the arc ignites.

NFC field, e.g., for user management and locking/unlocking the power source with an NFC card or fob

Configured main settings and additional functions at a glance (e.g., welding process, operating mode, polarity, HF).

The 7″ color display is even easy to operate while wearing welding gloves.

In this mode, the display size is increased by 40% and only the main work parameters are shown. This ensures clarity and means that the display can also be read easily from a distance.

With this function, you can save all the parameters for recurring welding tasks, and retrieve them quickly and easily whenever you need them.

The welding wire is fed automatically through the hosepack and welding torch at the touch of a button without having to open the feed rollers. None of the shielding gas escapes during this process.

If it has not been used for a while, the hosepack can be flushed with shielding gas by pressing the gas test button. That way, the gas shield is already in place when the arc ignites.

NFC field, e.g., for user management and locking/unlocking the power source with an NFC card or fob

iWave 190i-230i

Easy and intuitive operation

  • Immediate graphic feedback whenever various welding parameters are changed
  • 4.3″ color plain-text display
  • than 30 language options
  • All work parameters located on 1st menu level
  • Easy to operate while wearing gloves
  • Status display: configured additional functions and main settings at a single glance
  • 5 EasyJobs and 3 user-defined parameters on 1st menu level
  • Configurable favorites button

User management

INDIVIDUAL AUTHORIZATIONS FOR DIFFERENT USERS

Complete control: the integrated authorization system allows you to assign individual permissions to each user. When someone logs in with a key card or fob, the system immediately knows what they are – and are not – allowed to do. And if you want the perfect solution for assigning and administering authorizations for multiple welding systems centrally, you need look no further than our Central User Management.

Easy administration on the welding system Create new users in just five steps: create and define role, create and define user, assign card, AND YOU’RE DONE.

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Easy locking and unlocking The welding system can be unlocked really easily with a card or key fob. You also have the option of using a dedicated NFC card.

Manage individual authorizations for each welding system This means people can only perform actions on the system for which they have been specifically authorized.

PC-based user management Efficiency savings of more than 90% (measured in clicks) when setting up an account for someone who needs access to 20 systems. Compared to creating the account directly on the welding system display

Central User Management A clear reduction in complexity: only one tool required to manage different systems.

Industry 4.0 ready

Full connectivity: contactless data transfer and authentication

Industry 4.0 performance levels: iWave supports all the main communication standards. Wirelessly connect peripheral devices to the welding system in next to no time – that means anything from high-tech welding helmets (such as the Vizor Connect) to remote controls. Use WLAN to integrate welding systems directly into your network for easy firmware updates.

WLAN

For complete network capability – to enable updates and use of the Smart Manager function without an Ethernet connection (data documentation).

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