KWS Provides Sludge Loadout System for Chemical Manufacturer

General Description

Since 1932, Stepan Company has been a global leader in manufacturing surfactants, polyurethane polyols, and key ingredients in consumer products like detergents, cleaners, and personal care items. Stepan also provides customized solutions for the agricultural, oil field and construction sectors. Over 70-percent of its products offer energy savings or reduced environmental impact. Stepan operates 20 modern productions facilities across 11 countries.

A Stepan production facility located in Winder, GA needed an automated sludge load out system. The new system dewaters the sludge and feeds directly to the KWS loadout system, which is designed to feed two roll-off dumpsters. The KWS sludge load out system includes three shaftless screw conveyors, six pneumatic slides, zero-speed sensing, and radar level sensing.

KWS Provided Automated Sludge Load Out System with Sensors and Controls

Design Parameters

Product Type: Sludge
Material Density: 60 Lbs. per Cubic Foot
System Capacity: 114 Cubic Feet per Hour
Duty: 24 hours a day, 7 days a week

KWS Advantages

The new dewatering loadout system is completely contained and automated, creating a very clean and efficient process. Reduced operator intervention and direct loading of sludge greatly reduces the man hours associated with operating the equipment. KWS designed the loadout system to fit in the limited space allowed and was able to assist the contractor during the installation and commissioning phase to ensure the new equipment met Stepan’s expectations.

Special Features

To withstand a corrosive environment and ensure long-term reliability, the KWS shaftless screw conveyors were constructed from 304 stainless steel. KWS engineered a custom inlet chute to create a smooth transition from the centrifuge, eliminating spillage and improving material flow.

For enhanced safety and system protection, the conveyor system was equipped with zero-speed switches to detect loss of screw rotation and automatically stop the system, preventing damage to downstream equipment. An emergency stop switch was also implemented to allow operators to instantly shut down a conveyor in the event of an unsafe condition, protecting personnel and equipment.

A non-contact radar level sensor was installed at the discharge chute of the distribution conveyors to accurately monitor the level of biosolids. This advanced sensor technology eliminates contact with the material, reducing maintenance and ensuring reliable performance.

To further protect the system, a plug switch from 4B Components was added to detect material buildup or blockages. The plug switch delivers early warning of obstructions, helping operators take corrective action before a shutdown or equipment failure occurs.

As with all KWS solutions, every component was engineered, manufactured, and tested in the USA to meet the highest standards of quality, durability, and on-time delivery—backed by unmatched customer support.

Customer Testimonial

“We’re extremely satisfied with the equipment and commissioning. KWS provided valuable support throughout the entire process from approval drawings to promptly addressing all our questions during installation.”

Project Engineer – Stepan Company