Westfalia separator(r) ecoforce has been re-designed from the bottom up to suit current customer requirements. The uniform concept involves a "modular" principle, allowing its engineering to be adapted to a customer's application-specific requirements even more simply and precisely than ever. The identical design for all model sizes makes things much easier for operating and maintenance staff.
Westfalia separator(r) ecoforce has been re-designed from the bottom up to suit current customer requirements. The uniform concept involves a "modular" principle, allowing its engineering to be adapted to a customer's application-specific requirements even more simply and precisely than ever. The identical design for all model sizes makes things much easier for operating and maintenance staff.
Westfalia separator(r) ecoforce has been re-designed from the bottom up to suit current customer requirements. The uniform concept involves a "modular" principle, allowing its engineering to be adapted to a customer's application-specific requirements even more simply and precisely than ever. The identical design for all model sizes makes things much easier for operating and maintenance staff.
Westfalia separator(r) ecoforce has been re-designed from the bottom up to suit current customer requirements. The uniform concept involves a "modular" principle, allowing its engineering to be adapted to a customer's application-specific requirements even more simply and precisely than ever. The identical design for all model sizes makes things much easier for operating and maintenance staff.
GEA Mechanical Equipment / GEAWestfalia Separator Group
Manages Everything, Needs Little, Lasts Forever Westfalia Separator ecoforce is convincing in its outstanding performance data and separation efficiency, topmost availability, identical construction of all model sizes, flexible equipment possibilities and special implemented service.
This newly developed generation of decanters has
been re-designed from the bottom up to suit current customer requirements, starting with all model sizes being of identical design. If you know one, you know them all, making things much easier for operating and maintenance staff. It also has a long-term positive impact on the availability of spare parts. The uniform concept involves a modular principle, allowing its engineering to be adapted to a customers application-specific requirements even more simply and precisely than ever. Subsequent modifications are also possible: the intelligent design means that individual components are easy and quick to replace. Decanters from GEA Westfalia Separator Group are well-known for their high separation efficiency and first-class throughput capacities. In this respect, decanters of Westfalia Separator ecoforce remain true to themselves. Applications which make high demands on material and machine engineering, in particular, require robust machines which carry out their tasks reliably. The new decanter series has been set up for these tasks consistently by means of constructively new features. Our Original Manufacturer Service system, Westfalia Separator directcare, was integrated specifically for this new range of decanters to ensure maximum availability of systems. Never before have customer expectations and requests for improvement been implemented more comprehensively than they have in this case, in the form of optional services which can be secured by contract. Westfalia Separator ecoforce is a customized system which is economic for the user and can moreover be planned in advance.
Westfalia Separator ecoforce
This is New Uniform design from small to large, modular concept, drive concept and service contracts for farsighted transparent cost planning the entire decanter program of GEA Westfalia Separator Group has been completely revised and simplified.
The identical design for all sizes is the most distinct
The new type of gears covers a differential speed
feature. Once you have learnt to install, operate
range of between 1 to 70 rev./min. with small
and service a decanter of the Westfalia Separator
modifications only. Thus, Westfalia Separator
ecoforce family, this know-how can be transferred
summationdrive can be employed for the entire range
to other model sizes effortlessly. The identical
of applications. Thus, an identically high maximum
appearance may be the most striking new feature of
speed torque is available for the entire range. In addi-
the new decanter, but the actual revolution is in the
tion, the gear unit is no longer located in the product
underlying concept of the modular design.
area of the decanter. Moreover, Westfalia Separator
summationdrive feeds in power only. Energy must
Never before has a decanter generation been devel-
not be circulated to be recovered again with a
oped for use in all applications at the same time.
lot of effort. Energy losses as they occur in other
Already the first developers line was based on a
solutions with backdrive are a thing of the past. This
complete catalogue of variants for the individual
also means that all additional electrical components
assembly groups. A basic construction was achieved,
used for energy recovery are no longer required. Belt
which meets all sorts of requirements from in-
drives which circulate power have disappeared as
numerable different applications, and on the basis
well. On account of the high efficiency of the drive,
of which the individual assembly groups can be
energy costs are saved.
combined freely. This fact produces considerable advantages for the customer. On the one
Together with the hardware, thus the decanter,
hand, the decanters can be set up precisely for
GEA Westfalia Separator Group offers service
the requirements of every application. The indi-
level agreements which provide maximum safety
vidual component parts can be supplied very
to the operator. Not only with respect to permanent
quickly as fewer different parts have to be ware-
operation of the machine, but also with respect
housed, thus the entire fleet of Westfalia Separator
to the height of costs. Within the framework of
ecoforce makes do with seven different gears only,
Westfalia Separator directcare, the customer can
for example. Moreover, as the individual parts are
choose between three different service level
being used in many different applications, the
agreements. They can be configured freely as a
customer can be sure that they have proved their
matter of principle; the idea of the modular set-up
worth. And, last but not least, the decanters can be
has been applied here as well. Whether full service
modified subsequently very easily and quickly on
at a fixed price or basic module: as required, the
account of the modular design.
customer can choose a degree of service which
meets his demands best.
In addition, the entire drive unit including gear has
been re-designed completely. Not only is it an in-house construction of GEA Westfalia Separator Group, the gears are manufactured in-house and are put through their paces on the in-house gear test bay in the centrifugal field as well.
Some Features just Run in the Family:
One for Outstanding Separation Efficiency and Throughput Decanters from GEA Westfalia Separator Group are renowned for their high degree of separation efficiency and maximum throughput capacities in that respect decanters from the Westfalia Separator ecoforce range remain true to themselves.
But above and beyond that, changes to the design of
The result is a differential speed which is always set
individual components, the use of simulation soft-
to the optimum, meaning that the decanter is per-
ware, new developments in materials technology
manently close to the process technology optimum.
and the modified drive concept have enabled us to
A unique characteristic feature of the new drive:
improve separation precision and throughput still
the Westfalia Separator summationdrive always
further.
provides the full torque across the entire differential
speed range, thus power drops are a thing of the past.
This has been achieved by improving rotor geometry and drive technology. The high rotor speeds
High speeds for maximum separation precision
and even further improved throughput.
which can be achieved as a result ensure maximum
separation precision and increased throughputs.
Super-deep pond means optimized flow
Improved flow characteristics in the bowl also make
characteristics. Optimized flow behavior due to
an important contribution here, with a super-deep
extreme pond depth: the maximum pond depth
pond design and optimized distributor for care-
possible depends on the values required for
ful acceleration when the product is fed in. Last
factors, such as dewatering, washing, classification
but not least, the drive concept, too, plays a central
and/or purification of liquids.
role, with the key concept here being scroll torque.
Optimally set differential speed at all times.
The newly developed, extremely flexible Westfalia
Full torque at all times, thus full performance
Separator summationdrive ensures maximum
at all times.
separation efficiency by automatically adapting the
high-torque drive to the feed conditions prevailing in the decanter.
Reliable and Rugged,
One for Continuous Duty The gears, bearings, lubricants, materials, steels and production of Westfalia Separator ecoforce scrolls and bowls are designed for continuous heavy duty.
It is precisely applications with heavy demands
High-quality protection from wear significantly
on material and engineering which require rugged
increases the service life of components in contact
machines to perform their jobs reliably. Novel design
with the product for example anything from com-
features of this new range of decanters ensure that
puter-controlled (and thus accurate) hard-facing of the
this objective is consistently met.
hardened metal cladding to tiles for the scroll.
The basic design has been changed: unlike previ-
The latest computer simulation software was used to
ous generations, all Westfalia Separator ecoforce
design the frame so that it has maximum dynamic
decanters are provided with external gears. This
stability even at high bowl speeds.
segregates the product space from the drive space,
which is particularly advantageous for hot-running
It goes without saying that only high-quality stain-
applications, as gears are much less exposed to high
less steels are used for all parts in contact with the
product temperatures, with a positive impact on
product.
service life. External gears. The lubrication concepts are also adapted to the respective requirements and are geared consistently
Oil lubrication of all bearings
for exacting demands.
to long service life: grease lubrication of the bearing
High-quality protection against wear.
is contained in the module. In case of higher demands
High degree of dynamic stability.
on machine and material for hot operation, at high
Use of high-quality stainless steels.
speeds and also in the food industry, bowl and scroll
bearings are supplied with oil lubrication without exception. On the larger decanters, oil lubrication of the bowl bearings is provided as standard, irrespective of the requirements of the respective application. The gear is likewise without exception supplied via oil lubrication.
One for Maximum Energy Efficiency
No more excessive dimensions: Westfalia Separator ecoforce can be tailored precisely to the quantities of your processes. Features such as the Westfalia Separator summationdrive and the new rotor geometry make a permanent contribution to energy efficiency.
The high-torque Westfalia Separator summationdrive
Through diverting the flow against the direction
always makes the optimum differential speed avail-
of rotation of the decanter, the jets generate an
able, with only power to be specific, only the power
additional pulse which drives the bowl.
actually required at any particular point being fed
in at all shafts. Intelligent kinematics combine or
Rotor geometry is important, too: bowls in super-deep
sum the outputs of both motors and then transfer
pond design ensure even higher energy efficiency in
this accurately to bowl and scroll. Energy feedback
addition to an extremely high degree of clarification.
is always accompanied by transmission losses due to
The value for the deep pond is defined by the ratio of
the real efficiencies of components such as frequency
the diameter of the solids discharged to the internal
converter, motor and generator. Such transmission
diameter of the bowl.
losses do not occur with the Westfalia Separator
summationdrive which results in energy savings
GEA Westfalia Separator Group designed the new
of up to 10 percent compared to other drives. This
family of decanters with a deep pond design, with
drive consequently does not need additional electrical
the result that optimized flow characteristics are
components for energy recycling or belt drives which
achieved in the bowl, clarification is improved
circulate power.
and there is less loss to friction when liquids are
discharged. The bottom line is a reduction of up to
Apart from the site space saved, the load on the shaft is
30 percent in specific energy consumption.
reduced and costs are reduced by lower energy losses.
The discharge power for the clarified liquid repre-
Customized decanter sizes.
sents a further source of energy consumption of the
Westfalia Separator summationdrive with
decanter. This factor can amount to up to 50 percent of
optimized power flow.
the total energy requirement of the decanter. Through
Super-deep pond design.
the application of energy jets, specially shaped weir
Significant reduction in specific energy
plates with an integrated deflection of the flow, the
consumption of up to 30 percent.
energy requirement of the decanter can be reduced
by up to 10 percent. The function of the energy jets is based on the principle of the Pelton turbine.
11
One for the Future:
Westfalia Separator ecoforce Never before has a decanter generation been developed for use in all applications at the same time. Already the first developers line was based on a complete catalogue of variants for the individual assembly groups. A basic construction was achieved, which meets all sorts of requirements from innumerable different applications, and on the basis of which the individual assembly groups can be combined freely.
The Westfalia Separator summationdrive with large
The new Westfalia Separator ecoforce can also be
differential speed ranges and rapid conversion
changed quickly and easily from open to closed
options, simple conversion from 2-phase to 3-phase
discharge of the liquid phase or from a 2-phase to
separation or upgrades for sanitary operations, gear
a 3-phase version, likewise thanks to the modular
sizes or bowl designs simple adaptation is part of
principle.
the concept of this new range of decanters.
Modern control software makes it easier for operatPlanetary gears in three torque sizes per machine
ing staff to deal safely with all phases of production.
type allow decanters to be adapted easily to modi-
At the same time, the measurement and control
fied process conditions or torque requirements. The
systems are ready to be flexibly adapted to advances
uniform construction of all sizes of decanter allows
in technology and thus to produce at optimum levels
them all to be converted rapidly.
in the long term.
The intelligent design of the Westfalia Separator
Modular principle: right from the beginning,
summationdrive means the new generation of
a catalogue of variants takes all sorts of require-
decanters has a drive concept with a broad control
ments from innumerable different applications
range for differential speed right from the outset.
This ensures that the decanter is always operating at the theoretical optimum. However, should a different differential speed range be required subsequently
into consideration. Module variants can be freely combined with each other, and thus permit subsequent modification. Reduction of complexity.
because the machine is to be used in a different pro-
Three gears sizes per machine type.
cess, for example the drive is very easy to convert
Gears do not have to be replaced if the machine
because the gears do not need to be replaced in the
is converted to a different differential speed
process.
control range. Easy adaptation of machine set-up to changed
The patented Westfalia Separator varipond system
allows the level of liquid in the bowl to be controlled quickly and automatically without any assembly steps and with the machine running, achieving a consistent concentration of discharged material, even if feed conditions fluctuate.
12
process conditions.
Service Already Included:
One for Maximum Availability with Westfalia Separator directcare Westfalia Separator directcare supplements every new-generation decanter with services to suit requirements. For the most exacting demands, proactive services such as Westfalia Separator wewatch online condition monitoring ensure permanent availability throughout the entire lifecycle, with costs completely under control.
The concept of supplying decanters plus service was
Optimum integration
designed from the outset to secure machine availability
The advice and support of Reliability Consultants
and thus your investment in the long term. Westfalia
forms the basis for optimum usage of existing
Separator directcare offers packages which combine
systems and the best possible integration of new
a technological leading edge with every commercial
process lines. With empirical values gained from over
requirement. Whether you want full service at a fixed
5000 systems installed all over the world and the
price or basic modules, you can select the service
latest analysis tools, we will collaborate with you in
level which corresponds most closely to your needs
working out a service concept perfectly customized
depending on your requirements. The aim of this
to your requirements. The recommended solution
new concept is to make sure that all the technical
has both a mechanical and a commercial basis,
and economic benefits of the new range of Westfalia
and always focuses on whichever optimum can be
Separator ecoforce decanters remain in full use to
achieved.
suit the customer throughout their entire service
lives. At the same time, lifetime costs including full
Whichever service level you select, Westfalia
service costs can be reliably calculated right from
Separator directcare will always ensure that you
the outset.
receive the comprehensively certified service
quality and expertise of the original manufacturer.
Online monitoring
Our close-knit, worldwide network of authorized
Westfalia Separator wewatch
workshops set up especially for the purpose means
Whether you are monitoring vibrations, temperatures,
you can rely on local support. Backed up by a highly-
the condition of bearings, torque, current consump-
qualified service team and a comprehensive service
tion or throughput, continuous proactive monitoring
portfolio, we reliably and consistently provide the
and diagnosis of trend values and current values in
following services to the state of the art and for
the systems using Westfalia Separator wewatch is
maximum customer benefit:
the recommended solution for customers who want
permanent maximum convenience and security. This
Qualified service advice.
is linked to reliable avoidance of unplanned machine
Technical customer service.
stoppages, a high degree of system reliability and
Original spare parts.
optimum planning of maintenance and moderniza-
Extensive training options.
tion measures. Condition monitoring is the step to
Authorized workshops.
take towards continuous, proactive servicing and thus
Conversion/upgrading of existing systems.
towards forward-looking and condition-based main-
Condition monitoring.
tenance.
Comprehensive exchange program for
wear parts. Service level agreements.
15
Beverage Technology
Dairy Technology
Renewable Resources
Chemical/Pharmaceutical Technology
Marine Energy Oil&Gas
Environmental Technology Engineering Second Hand Machinery Original Manufacturer Service
The information contained in this brochure merely
serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries. Westfalia, Westfalia Separator, varipond and wewatch are registered trademarks of GEA Mechanical Equipment GmbH. Printed on chlorine-free bleached paper www.papp.cc B_WS-11-10-0020 EN Printed in Germany Subject to modification
