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Kason Corporation

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  1. Distillery Turns Stillage Waste Into Revenue With Centrifugal Sifter LEWISVILLE, TEXAS Bendt Distilling Company, a maker of handcrafted whiskeys, uses a centrifugal sifter to turn spent grain byproduct into saleable livestock feed while recovering the liquid sour mash, a valuable component in the distilling process. Founded in 2012 by Natasha and Ryan DeHart, Bendt Distilling currently produces 1200 barrels per year of straight whiskeys and whiskey blends, employing traditional distillation methods. Dewatering stillage centrifugally Grains including wheat, rye, barley malt, oats, corn and triticale (a hybrid of wheat and rye), are ground to the consistency of coarse flour, then mixed with water, cooked, mashed and fermented. After fermentation, the strip run (first round of distillation) separates out the alcohol from the fermented mash. The remaining grain/ water mixture called “stillage” consists of water containing 5 to 10 percent grain solids. In its watery state, the stillage is a waste product to the distillery but contains enough grain and nutrients to be useful to farmers as livestock feed. Originally, Bendt pumped the stillage into a 20-cubic yard disposal container for pick-up by farmers at no charge. This saved the company disposal costs as long as the stillage was collected. If it wasn’t, the company had to pay to have it hauled away. In researching a solution, DeHart read about another distillery’s use of a centrifugal sifter to dewater stillage. He contacted the manufacturer, who evaluated Bendt’s application and recommended a Kason model MO-3BRG. The stillage now accumulates in a 10,000 gal (38,000 l) holding tank, and is pumped about once a week into the centrifugal sifter. The water/ grain mixture passes into the sifter’s horizontally-oriented cylindrical screening chamber where rotating helical paddles accelerate the mixture against the screen by centrifugal force. Liquid passes through the screen, exits through a flanged discharge chute at the base of the sifter and flows into discharge piping. Oversize grain solids are propelled along the cylindrical housing until they exit the downstream end of the cylinder and gravity feed into a 20 cubic yard (15.3 cu m) enclosed container. The centrifugal sifter operates at a rate of 30-40 gal/min (114 to 151 l/min), so emptying the tank takes four to five hours. The unit is 74 in. (1880 mm) long, including its motor, and 32 in. (813 mm) high. The stainless steel wedge wire screen is sized at 140 mesh (105 micron). After dewatering, the grain still contains about 80% water but has a texture “you can hold in your hand,” DeHart says. A full container holds about 15 tons (13.6 m.t.) of grain, which is the yield of 20,000 gal (75,708 l) of stillage. The liquid, called sour mash, is recovered and stored to add to subsequent fermentation batches. “Using sour mash saves water, provides flavor consistency, and naturally adjusts the pH,” Ryan DeHart says. Customizing the solution Working with Kason’s applications engineers, Bendt Distilling Company identified solutions for problem areas, such as dealing with the sludgy consistency of the stillage at the bottom of the holding tank, which could cause the sifter to stall, and dealing with stillage containing corn (a byproduct of bourbon production), that holds more water than the other grains and tends to become spongy. Kason’s solution was to run the unstable 208 3-phase supply more efficiently at a higher voltage by adding a transformer to step up the voltage. For the corn stillage, changing the screen mesh size and installing a higher-pitch paddle assembly pulls the stillage across the screen cylinder effectively while maintaining the same throughput and de-watering performance without any clogging or imbalance, allowing unattended operation. Ease of cleanout was a big factor in choosing the sifter, DeHart says. “We can clean it quickly, getting to all the pieces. With the three-bearing design, the front of the sifter opens for cleaning and changing parts. Internal components slide freely from the shaft.” The sifter’s compact design was also important for the distillery, as was its low power requirements “with just a 3 hp (2.2 kW) motor,” DeHart says. Heavy duty construction also suited the distillery as the sifter is installed outdoors. Finally, DeHart appreciates that the unit is relatively quiet. “We’re really happy with the setup,” DeHart says. “It’s a good low-cost solution compared to what else is on the market for separating the grain at a fast speed.” Turning an expense into revenue Partnering with a national feed company, the distillery worked out an agreement with a local cutting horse farm to take the spent grain. Under a profit-sharing agreement with the feed company, the distillery receives income in addition to having the spent grain hauled away at no cost The Kason centrifugal sifter has provided a “win-win” solution, DeHart says. “A waste byproduct for us is a useful product for somebody else.” Kason Corporation (973) 467-8140 | info@kason.com | www.kason.com Jim Ling North American Sales Manager Kason Corporation – Regional Sales Office Southgate, KY 41071 Tel. / Fax 270-60-KASON Review my background on LinkedIn Kason-Bendt Distillery.pdf
  2. I thought they were still operating under new ownership after Greg Lowe and his partners sold the business - but I too see the "last call" out there on the webpage unfortunately
  3. Remember, not all Centri-Sifters are created equally either. I can tell you about suitability of particular machines. Be careful in the used equipment market, you may find what "looks right" from the outside but which you'll need to upgrade on the inside. It may be a real fight to get things up and running as 8 Feathers can attest - but consider the new machineto get off on the right foot and also think about alternative financing options should you want to find a creative way to get a machine into your distillery. I can point you in the direction of a few capital companies or you may be aware of your own locally. Section 179 of the IRS code may be helpful too. Section 179 is one of the most important tax codes for business owners, It lets you deduct all (or part) of the cost of equipment that is purchased or leased and put into place before the end of the year. Contact me at 270-60-KASON or JLing@KASON.com about screening processes or to give you more information on financing thru a third party. GG-0386 Eight Feathers Distillery CH-Brewer Distiller Int'l Nov 2019.pdf
  4. From #ThrowBackThursday, let's talk beer! We are going to take you back to a time when our CENTRI-SIFTER™ Centrifugal Dewatering Screener saved the Alaskan Brewery Company a ton of capital. If you don’t already know this, beer making begins with cooking grains. Between batches, the brew vessels must be cleaned. At the time, the Alaskan Brewery Company had a problem with the bigger grain kernels settling down densely into the bottom of the tank, going down the drain into the wastewater system, bonding with the sludge, and jamming the pump. Here is what we put into our machine, and how we solved the problem: https://goo.gl/1uKwhV #TBT #AKBeerweek #ClientLove https://www.linkedin.com/company/kason-corporation/
  5. Presses offer a very dry discharge, but for high flows, the size of the equipment increases as do other ancillary equipment needs. In some cases the Kason can be used to "thicken" the sludge to allow use of smaller presses for a great solution and very dry cake. It really depends on what one is trying to accomplish. In this instance, for the required flows and dryness, the Kason Centri-Sifter offered the most reasonable results.
  6. until
    Process Expo September 19 – 22, 2017 McCormick Place – Chicago, IL Booth #4404 | Use code 95393 for Free Registration! https://registration.experientevent.com/ShowFPS171/
  7. KASON CORPORATION 67-71 East Willow Street Millburn, NJ 07041 Tel: 973-467-8140, ext 211 Fax: 973-258-9533 Website: http://www.Kason.com E-Mail: JLing@Kason.com Model MO-SS Centri-Sifter in 8 Feathers Distillery The best equipment to remove spent grains from their distillery’s discharge stream was found by 8 Feathers Distillery to be Kason Corporation’s Centri-Sifter. Substantially less expensive than alternatives from other manufacturers, the solution simplified equipment needs. Once grain is fermented or distilled, it requires disposal by a means acceptable to the local community. Craft distilleries, often located within a Publicly Owned Treatment Works (POTW) service area, require strict limits on solids discharged in the waste stream. Since many craft whiskey distilleries use hammer mills to grind grains, the resulting byproduct is too fine to allow lautering as the grain removal method, so an aggressive process like the Centri-Sifter must be used. When originally presented with 8 Feathers process challenge, Kason Corporation offered the MOS Centri-Sifter with a heavy duty screen as the best separation option – though possible to accomplish with a traditional Vibroscreen, the Centri-Sifter allows higher flow rates while also producing a discharge of spent grain with less remaining free water. After sending a sample of the material to be separated, Kason Corporation conducted a free process test and suggested a screen mesh and paddle design to separate material and minimize the risk of screen blinding. For a small distillery facing these restrictions, the challenge to economically remove spent grains becomes limited and daunting. Trucking of stillage discharge is cost prohibitive with high water content so producers seek solutions to separate grain from liquid for efficient disposal. Before choosing Kason Corporation’s Centri-Sifter, other separation methods identified included passive settling systems, chemical flocculation, or mechanical separation. Among mechanical separation options considered were filter presses, screw presses, and centrifugal separators. Initial studies indicated all these as viable choices where presses are the most expensive and centrifugal sifters are the most cost effective solutions. 8 Feathers Distillery studied these options and concluded that mechanical separation using Kason Corporation’s Centri-Sifter offered the best combination of cost, function and efficiency. Though settling tanks provide effective separation, the process requires multiple holding tanks with excessive time and space requirements. Use of chemical flocculation renders the spent grains unfit for use as animal feed – instead they become solid waste which must be disposed of in landfills. A filter press sized to meet distillery needs requires a large compressor to drive air diaphragm pumps. Without adding some form of solids coagulant to the process stream, the filter cloths require extensive cleaning after each use. The chemicals which enhance the solids collection render the collected grains unacceptable for use as animal feed. These additional equipment and chemical needs make filter presses, though effective, the most expensive option. Screw presses are appropriate for general industrial use but lack features to clean adequately for a distillery. No press fit within budget, flowrate and footprint constraints of 8 Feathers. While mechanical separation is the best solids removal method, Kason Corporation’s Centri Sifter minimizes cost, time, space, and environmental impacts best within the types considered. After purchase and prior to installation, Kason Corporation supplied mechanical drawings to allow 8 Feathers to construct the necessary platform to house the Centri-sifter. Once the unit arrived it was installed without issue and began initial testing immediately. The results were as good, or better, than expected. The unit processed a 1500 gallon, 40% solid test sample fed at 40gpm, without any screen blinding or degradation of performance. The separated grain was suitably dry for transport by truck. Now, the MOS Centri Sifter provided by Kason Corporation is in production at 8 Feathers Distillery and provides a key function in POTW compliance while still allowing captured solids to be used for animal feed in an efficient and cost effective grain separation solution. Links to Videos: Kason at 8 Feathers - Video 1 Kason at 8 Feathers - Video 2 Kason at 8 Feathers - Video 3 Kason at 8 Feathers - Video 4 Kason Centri-Sifter in 8 Feathers Distillery.pdf
  8. Many people on this forum have expressed an interest in centrifugal sifters for the dewatering applications that are common in the distilling industry. Kason Centri-Sifters work very well for these applications. Kason will be exhibiting our Centri-Sifters at the upcoming International Powder & Bulk Solids Show at the Donald E. Stephens Convention Center in Rosemont, Illinois. The show runs May 3rd through 5th. This is a great opportunity to see the equipment in person. My application engineering colleagues and I will be available to answer questions and discuss your individual needs as well. I have free passes to the show available for those who are interested. Please send me a message/email or give me a call if you are interested in attending. Please visit us at Booth #2107. Mike Hart Application Engineer Kason Corporation 973-467-8140 ext. 129 mhart@kason.com
  9. Thanks Sim, Please do not hesitate to email or call me if I can be of assistance or if you would like to bounce ideas around. Mike Hart Kason Corporation mhart@kason.com 973-467-8140 ext. 129
  10. Sim, I hope that the new machine is working well for you. Kason offers competitive pricing on replacement screens for all manufacturers of vibratory screeners. We would just need to know the diameter of your machine. There are many different screen mesh sizes available for these vibratory screeners. The Kason Mesh Chart can be found at the following link: http://www.kason.com/images/BB-1091_MeshChart2013.pdf We typically use the Market Grade or Tensile Bolting Cloth (TBC) screens on our Vibroscreen Separators. The Mill Grade is also available but is not as common. TBC screens are popular because they allow for a higher percentage open area than the market grade for fine mesh screens. Mike Hart Kason Corporation mhart@kason.com 973-467-8140 ext. 129
  11. We have multiple size units for both the Vibroscreen and Centri-Sifter. In addition, many of these models are offered in both new and factory refurbished options. The cost of the unit and replacement screens will vary depending on the size of the machine. We offer competitive pricing for replacement screens on other manufacturers' screeners as well. If you would like me to provide pricing for your specific application, please send me a message or email. The most important information required when sizing a unit is the desired capacity in GPM, the percentage of solids in the feed material and the size of the solids. If you are unsure of the size of the solids or any other information, Kason can help. We offer free lab testing at our facility in New Jersey. This can help to determine an appropriate screen mesh size and confirm the machine sizing. Screens are easily changeable on our machines. In most cases, the screens can be swapped in less than 10 minutes when you are changing grinds. - Mike Hart Kason Corporation mhart@kason.com 973-467-8140 ext. 129
  12. Hi Sim, Kason has a great deal of experience dewatering spent grains. We manufacture both vibratory and centrifugal screeners in the USA at our factory in Millburn, NJ. The vibratory screener (Vibroscreen) will be able to dewater the solids adequately at low rates. However, our centrifugal screener (Centri-Sifter) will be able to get the solids drier since the Centri-Sifter applies force to help push water through the screen. We have both new and refurbished Vibroscreens and Centri-Sifters available. The Vibroscreen will be less expensive than the Centri-Sifter. Please feel free to send me and email/message or give me a call if you would like to discuss your application further. Mike Hart Application Engineer Kason Corporation 973-467-8140 ext. 129 mhart@kason.com
  13. Kason offers a centrifugal dewatering sifter that may be a good solution at a lower price. Please PM me if anyone is still interested. Mike Hart Application Engineer 973-467-8140 ext. 129
  14. Pete, The Vibroscreen Separators are good solution for a de-watering as well. The solids will tend to come out a little bit wetter using the Vibroscreen than using the Centri-Sifter since the Vibroscreen relies on gravity to get liquid through the screen rather than forcing liquid through the screen. You are correct that the Vibroscreen will be less likely to break down soft solids than the Centri-Sifter since it has a gentler action. Small Vibroscreen Separators do start at a lower price point and they are suitable for low flow rates. If you are interested in a quote, please send me an email or message. Mike Hart mhart@kason.com
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