Tyson Foods Replacement Screws

Introduction

Tyson Foods is one of the world’s largest food companies and a leading producer of protein products. The Tyson Foods facility in Madison, Nebraska, required a replacement screw conveyor for a demanding application during a planned maintenance outage. KWS provided a custom-made solution designed for improved performance, increased reliability, and on-time delivery.

Challenge

The existing conveyor was experiencing excessive wear and bulk material buildup, resulting in increased maintenance and reduced efficiency. Tyson required close-tolerance screws with heavy-duty construction to operate within troughs lined with AR235 abrasion-resistant trough liners. The screws also needed to operate as a continuous helix, without intermediate hanger bearings, to eliminate accumulation points. Delivery was critical because any delay would impact the planned outage schedule and increase production downtime.

KWS Advantage

KWS designed and manufactured a six replacement screws with close-tolerance outside diameter along with eleven abrasion-resistant AR235 trough liners. Each screw was built with a 15-7/8-inch outside diameter, 3/8-inch thick flights continuously welded on both sides, and special 5-inch Schedule 120 pipe for maximum strength.

The screws were bushed and drilled on each end so they could be close-coupled and clocked to create a continuous helix. This design eliminated gaps between screw sections and prevented bulk material buildup at transition points. KWS also provided bare pipe at the discharge end to promote smooth material flow. The screws, close-coupling shafts, and associated hardware arrived on site well ahead of the schedule shutdown and installed perfectly.

Eleven AR235 Abrasion Resistant Trough Liners Delivered to Site

Heavy Duty Screws Mounted on 5-Inch Schedule 120 Pipe