Rail Car Unloading System for New York Sugars in Rochester, NY

General Description

For over 99 years, New York Sugars has partnered with food manufacturers to deliver high-quality sugar ingredients backed by dependable service. Both dry sugar in granulated and powder form as well as liquid sugar products are produced at the Rochester facility.

New York Sugars reached out to KWS for help designing a rail car unloading system. The solution consisted of a series of screw feeders and screw conveyors to transfer raw sugar from beneath rail cars to downstream processing equipment.

Granulated Sugar is Unloaded from Rail Cars

Design Parameters

Product Type: Raw Sugar
Material Density: 50 Lbs. per Cubic Foot
Capacity: 1200 Cubic Feet per Hour
Duty: Intermittent

KWS Advantages

KWS engineering personnel collaborated closely with New York Sugars to ensure the equipment would reliably capture raw sugar discharged from railcars and deliver it to the downstream process. Using advanced 3D CAD tools, KWS created a comprehensive three-dimensional model of the screw feeders and inclined screw conveyors arranged in series. Support locations were carefully coordinated with New York Sugars to guarantee accurate fit-up during installation. KWS’s ability to provide custom-engineered solutions and accelerate manufacturing enabled New York Sugars to rapidly integrate their new material-handling system.

KWS Special Features

KWS screw feeders were utilized underneath rail cars to meter raw sugar to downstream conveyors. KWS screw feeders employed a stepped pitch configuration beneath the inlet for precise metering. The screw feeders were engineered to manage maximum material loads without overloading the motor. Each unit featured an inverter-rated motor with 10-to-1 turndown capability, providing extensive capacity range flexibility.

KWS utilized split tubular housings for the steep inclined screw conveyors to achieve the 35-foot vertical discharge height from underneath the rail cars. Reduced pitch screws enhanced conveying performance and prevented material backflow over the screw flights. Additionally, split tubular housings provide superior access to internal components, simplifying maintenance procedures compared to conventional non-split tubular designs.

To avoid the use of hanger bearings—which are unsuitable for steep inclines—KWS engineered a series of long incline conveyors capable of reaching the necessary discharge elevation. The steep inclined screw conveyors feature a robust 6-inch pipe, maximizing screw span while keeping deflection under 3/16-inch to prevent contact between the screw and the housing.

Because sugar is classified as a combustible dust hazard, strict safety considerations were required. When suspended in air at certain concentrations, sugar dust can form an explosive atmosphere if exposed to ignition sources such as sparks or hot surfaces. To mitigate this hazard, KWS specified explosion-proof motors rated for Class II, Division 2 environments. These motors incorporate sealed housings and protective design elements that prevent internal arcing or hot components from igniting surrounding dust, ensuring safe, reliable operation in sugar-handling applications.