Considering Grinder Options
Decisions. Decisions. It’s getting tougher to pick the grinder that’s right for a particular recycling or landclearing operation. But that’s a good thing; improvements have been made to machine features, making the distinction between tub grinders and horizontal models more obvious. And, once a buyer has settled on grinder type, a whole array of options and horsepower ranges await them. Chris Nichols, Product Manager for the Vermeer Environmental Product Group, gives us advice to get through all of the choices and help make the decision easier.
For many years, both types (tub grinders and horizontal grinders) have been successful in the market. This used to in-and-of-itself put manufacturers head-to-head — few used to offer both. Vermeer is one manufacturer that now does, which allows Nichols to objectively evaluate their advantages.
“Both types of grinders excel in conditions and applications that match up with their capabilities,” he says. In short, tub grinders generally perform better with heavy, large-diameter material such as stumps and root balls; if processing longer raw material is the consistent application, a horizontal model may be the best choice.
“In some materials, a tub grinder is perceived to have a higher production rate, but the horizontal models may have a distinct advantage when it comes to longer, bushier material,” Nichols says. “This is mainly because the tub is only so deep, and when processing the longer stuff, long branches may be difficult to feed. Horizontal models have the long feed table and conveyor that guides material into the grinder, avoiding the sometimes tedious task of material placement and manipulation.”
He adds that extra-long feed tables on trailer-mounted Vermeer horizontal grinders allow for loading of long material without additional cutting. This could be extremely beneficial in landclearing, recycling or storm cleanup applications.
Also, smaller loading equipment can be used for horizontal grinders, because they typically have a lower feeding height than a tub grinder. This could be a major factor, depending on the auxiliary equipment that a buyer or renter has on-site.
These grinder “categories” sometimes come with options that are specific to each. For example, Vermeer offers both track-mounted horizontal units and conventional towed models. In a situation where a single job site may have several debris piles — such as a landclearing job, the self-propelled track-mounted option can be highly efficient, Nichols says. So rather than having to tow the machine short distances, it can be moved by the operator, possibly into areas where it could not be towed.
Vermeer tub grinders, on the other hand, offer both loader and non-loader options.
Among the primary advantages of having a grapple loader on your tub grinder is better visibility of the tub; the loader cab provides excellent view of the tub cavity, so operators can load material more efficiently. It also helps the operator identify and clear contaminants mixed in with material. Self-contained loaders also eliminate the need for extra pieces of equipment, because transporting or renting a loading unit is not required.
Non-loader machines are common on work sites that include a fleet of multi-purpose loading equipment. Some non-loader tub grinders require multiple auxiliary loaders to meet the production capabilities of the machine.
Grinders on the market range from 100 HP to 1600 HP. Two things should be considered when selecting a size: volume and size of material to be processed and necessary mobility.
“Customers that represent a municipal landfill or private recycling operation, for example, may require a unit with high-volume capacity — it’s likely that a high daily volume of material can be expected in one central location,” Nichols says. “In this case, setup and mobility of the unit is not nearly as important as the necessary capacity.”
So now a buyer has settled on grinder type, options and size. In addition to resulting in more choices and more customized “fits” for certain operations and applications, advancements are also addressing what have in the past been two primary concerns about owning and using any type of large grinder: maintenance and safety.
As with any machine, proper preventive maintenance for a grinder is crucial to its longevity and productivity. Hammers, teeth, hammer shafts, anvils and screens are high wear items. Because of the difference in types of grinding materials and varying amounts of use from application to application, it is difficult to formulate a specific “rule of thumb” for average wear or longevity. Key variables include how well the raw material is cleaned, how fine the material is ground and how effectively the operator prepares the material.
Some grinder owners have in the past resisted regular maintenance of teeth and hammers, particularly because of the time involved. “It used to take up to a day to replace these components,” Nichols says. “And, if hammers are allowed to wear without proper maintenance, the hammermill could go out of balance and its vibration will cause excessive bearing wear and other vibration-related issues.”
Vermeer is one manufacturer to address this issue with their patented Duplex Drum System for tub and horizontal grinders. It offers a 35 percent increase in rotational inertia with a 10 percent weight reduction, Nichols says. And, it offers the operator the ability to change out any individual hammer within minutes without removing other hammers. It is much more efficient than the conventional “pin and plate” drums that have dominated the market in the past. The hammers also reverse for nearly double the life span, and the drum skin adds life by protecting them from wear and tear.
Because of the machines’ very nature, owners should also realize that grinders are very aggressively processing material, so there may be times when debris is thrown, especially if prohibited objects are mistakenly introduced into the grinder.
This drove Vermeer to develop their patented Thrown Object Restraint System (TORS) for tub grinders and the Thrown Object Deflector (TOD) for the horizontal models. The TORS can reduce the amount and distance of thrown objects down to 1/5 of that with normal grinders (without a system like this), allowing crews to operate the machine in a much smaller area. Vermeer tub grinders also feature a Falling Object Canopy, which is positioned directly above the ground control panel providing falling object protection for the operator standing at the controls. The tub and horizontal models feature standard remote-control operation too, which can position the operator well out of the restricted areas.
Where is the market headed?
“Any equipment owner desires value for his money — a good return on investment,” Nichols says. “This is maximized by increased productivity and minimal downtime. So manufacturers like Vermeer are coming up with innovations that increase productivity and efficiency on the job site, make maintenance easier, increase the longevity of the unit, and include innovative safety features.”
This will continue to be the norm, he adds. Manufacturers will always strive to create components and options that help customers maximize the return on investment, in processed material volume and uptime of the machine.
Following taking ownership, buyers are in the homestretch, but Nichols says there are still some critical things to remember. Every equipment owner should follow the maintenance recommendations of the equipment manufacturer, he stresses. Keeping a regular maintenance program will increase the life of a grinder. For example, it is important to check the hammers and teeth every day; overlooking or ignoring potential problems can lead to decreased productivity or unnecessary wear and tear.
In case something would break down, it is important to have parts and mechanics trained on grinder maintenance and operation. Equipment dealership personnel are valuable resources in these instances.
Nichols believes that, above all of this, it is most important that buyers diligently evaluate all the makes, models, sizes, and machine options on the market.
For many years, both types (tub grinders and horizontal grinders) have been successful in the market. This used to in-and-of-itself put manufacturers head-to-head — few used to offer both. Vermeer is one manufacturer that now does, which allows Nichols to objectively evaluate their advantages.
“Both types of grinders excel in conditions and applications that match up with their capabilities,” he says. In short, tub grinders generally perform better with heavy, large-diameter material such as stumps and root balls; if processing longer raw material is the consistent application, a horizontal model may be the best choice.
“In some materials, a tub grinder is perceived to have a higher production rate, but the horizontal models may have a distinct advantage when it comes to longer, bushier material,” Nichols says. “This is mainly because the tub is only so deep, and when processing the longer stuff, long branches may be difficult to feed. Horizontal models have the long feed table and conveyor that guides material into the grinder, avoiding the sometimes tedious task of material placement and manipulation.”
He adds that extra-long feed tables on trailer-mounted Vermeer horizontal grinders allow for loading of long material without additional cutting. This could be extremely beneficial in landclearing, recycling or storm cleanup applications.
Also, smaller loading equipment can be used for horizontal grinders, because they typically have a lower feeding height than a tub grinder. This could be a major factor, depending on the auxiliary equipment that a buyer or renter has on-site.
These grinder “categories” sometimes come with options that are specific to each. For example, Vermeer offers both track-mounted horizontal units and conventional towed models. In a situation where a single job site may have several debris piles — such as a landclearing job, the self-propelled track-mounted option can be highly efficient, Nichols says. So rather than having to tow the machine short distances, it can be moved by the operator, possibly into areas where it could not be towed.
Vermeer tub grinders, on the other hand, offer both loader and non-loader options.
Among the primary advantages of having a grapple loader on your tub grinder is better visibility of the tub; the loader cab provides excellent view of the tub cavity, so operators can load material more efficiently. It also helps the operator identify and clear contaminants mixed in with material. Self-contained loaders also eliminate the need for extra pieces of equipment, because transporting or renting a loading unit is not required.
Non-loader machines are common on work sites that include a fleet of multi-purpose loading equipment. Some non-loader tub grinders require multiple auxiliary loaders to meet the production capabilities of the machine.
Grinders on the market range from 100 HP to 1600 HP. Two things should be considered when selecting a size: volume and size of material to be processed and necessary mobility.
“Customers that represent a municipal landfill or private recycling operation, for example, may require a unit with high-volume capacity — it’s likely that a high daily volume of material can be expected in one central location,” Nichols says. “In this case, setup and mobility of the unit is not nearly as important as the necessary capacity.”
So now a buyer has settled on grinder type, options and size. In addition to resulting in more choices and more customized “fits” for certain operations and applications, advancements are also addressing what have in the past been two primary concerns about owning and using any type of large grinder: maintenance and safety.
As with any machine, proper preventive maintenance for a grinder is crucial to its longevity and productivity. Hammers, teeth, hammer shafts, anvils and screens are high wear items. Because of the difference in types of grinding materials and varying amounts of use from application to application, it is difficult to formulate a specific “rule of thumb” for average wear or longevity. Key variables include how well the raw material is cleaned, how fine the material is ground and how effectively the operator prepares the material.
Some grinder owners have in the past resisted regular maintenance of teeth and hammers, particularly because of the time involved. “It used to take up to a day to replace these components,” Nichols says. “And, if hammers are allowed to wear without proper maintenance, the hammermill could go out of balance and its vibration will cause excessive bearing wear and other vibration-related issues.”
Vermeer is one manufacturer to address this issue with their patented Duplex Drum System for tub and horizontal grinders. It offers a 35 percent increase in rotational inertia with a 10 percent weight reduction, Nichols says. And, it offers the operator the ability to change out any individual hammer within minutes without removing other hammers. It is much more efficient than the conventional “pin and plate” drums that have dominated the market in the past. The hammers also reverse for nearly double the life span, and the drum skin adds life by protecting them from wear and tear.
Because of the machines’ very nature, owners should also realize that grinders are very aggressively processing material, so there may be times when debris is thrown, especially if prohibited objects are mistakenly introduced into the grinder.
This drove Vermeer to develop their patented Thrown Object Restraint System (TORS) for tub grinders and the Thrown Object Deflector (TOD) for the horizontal models. The TORS can reduce the amount and distance of thrown objects down to 1/5 of that with normal grinders (without a system like this), allowing crews to operate the machine in a much smaller area. Vermeer tub grinders also feature a Falling Object Canopy, which is positioned directly above the ground control panel providing falling object protection for the operator standing at the controls. The tub and horizontal models feature standard remote-control operation too, which can position the operator well out of the restricted areas.
Where is the market headed?
“Any equipment owner desires value for his money — a good return on investment,” Nichols says. “This is maximized by increased productivity and minimal downtime. So manufacturers like Vermeer are coming up with innovations that increase productivity and efficiency on the job site, make maintenance easier, increase the longevity of the unit, and include innovative safety features.”
This will continue to be the norm, he adds. Manufacturers will always strive to create components and options that help customers maximize the return on investment, in processed material volume and uptime of the machine.
Following taking ownership, buyers are in the homestretch, but Nichols says there are still some critical things to remember. Every equipment owner should follow the maintenance recommendations of the equipment manufacturer, he stresses. Keeping a regular maintenance program will increase the life of a grinder. For example, it is important to check the hammers and teeth every day; overlooking or ignoring potential problems can lead to decreased productivity or unnecessary wear and tear.
In case something would break down, it is important to have parts and mechanics trained on grinder maintenance and operation. Equipment dealership personnel are valuable resources in these instances.
Nichols believes that, above all of this, it is most important that buyers diligently evaluate all the makes, models, sizes, and machine options on the market.
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