KWS Manufacturing

Metering and Conveying Shredded Fiberglass at CTA Acoustics in Corbin, KY

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Plant Name and Location

CTA Acoustics
Corbin, NY

General Description of the Application

CTA Acoustics, Inc., headquartered in Madison Heights, Michigan, is a leader in the innovation and development of acoustical and thermal insulation for the building products and automotive industries. CTA Acoustics has a manufacturing complex located in Corbin, Kentucky to produce a variety of fiberglass acoustical and thermal insulation products. CTA Acoustics’ products can be found throughout vehicle line-ups such as Ford, General Motors and Fiat Chrysler.

CTA Acoustics’ plans to redesign of their production facility lead them to contact KWS. KWS designed and supplied three multi-screw live bottom screw feeders, five live bottom collection screw conveyors, and one reversible screw conveyor to fit the needs of the redesign. One of the live bottom screw feeders is designed to receive fiberglass directly from a heavy-duty, industrial shredder. This live bottom feeder discharges the shredded fiberglass into a pneumatic conveying line where is then conveyed to a KWS reversible screw conveyor. The reversible screw conveyor is used to discharge the shredded fiberglass into one of two bulk bags. Two of the live bottom screw feeders are designed to unload the shredded fiberglass from those bulk bags suspended above the feeder’s receiving hopper. This live bottom feeder also discharges into a collection screw conveyor that conveys the shredded fiberglass to a pneumatic conveying line. It is then conveyed to other processes to be blended and molded to make the thermal and acoustic insulation.

Design Parameters of Application

  1. Product Type: – Shredded Fiberglass
  2. Material Density – 4 Lbs. per Cubic Foot
  3. Conveyor Capacity – 750 Cubic feet per Hour
  4. Duty – 24 Hours per Day, 7 Days per Week

Advantages Provided by KWS

KWS engineers and local field representatives worked side by side with CTA Acoustics to develop the ideal solution. KWS collaborated with the shredder, pneumatic conveying, and bulk bag unloader manufacturers to ensure the live bottom feeders and screw conveyors would fit within the dimensional constraints of the other equipment. Custom inlets and discharges were designed to guarantee seamless connections in the field. These custom flanged connections allow CTA Acoustics to maintain a clean, dust-tight operation.

Special Features of KWS Design

The quadruple live bottom screw feeders were designed with four independent gearmotors, one per screw. The independent gearmotor arrangement allows for smaller power transmission components, fewer maintenance components, and system redundancy when compared to a single gearmotor configuration with gears or chain & sprocket connections. Should unexpected maintenance be needed on one screw, CTA Acoustics will still be able to operate the facility at a reduced capacity with the remaining screws still in operation while maintenance is completed on the other.

The discharge end on the collection screw conveyors where fitted with double flights and breaker bars. The double flight is used to provide a more even discharge of the shredded fiberglass into the pneumatic conveying line and eliminate surging. The breaker bars aid the irregularly shaped fiberglass material to transition into the conveyor’s discharge and prevent plugging.

Testimonial

"KWS has done great work in the past and we will be purchasing more equipment in the future from KWS."

Caitlyn Bromley, Product Development Engineer – CTA Acoustics, Inc.

Metering and Conveying Shredded Fiberglass  at CTA Acoustics in Corbin, KY

Quadruple Screw Live Bottom with Independent Drive Units

Metering and Conveying Shredded Fiberglass  at CTA Acoustics in Corbin, KY

Collection Screw Conveyors Transfer Shredded Fiberglass to Other Processes

Metering and Conveying Shredded Fiberglass  at CTA Acoustics in Corbin, KY

Collection Screw Conveyors Transfer Shredded Fiberglass to Other Processes

Metering and Conveying Shredded Fiberglass  at CTA Acoustics in Corbin, KY

Reversible Screw Conveyor Transfer Shredded Fiberglass to Bulk Bags


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