KWS Manufacturing

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX

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Owner Name and Location

Encore Wire Corporation
McKinney, TX

General Description of the Application

Encore Wire is a leading manufacturer of copper and aluminum residential, commercial, and industrial building wire. Not only does Encore manufacture copper wire from pre-consumer raw materials, but they are also one of the only copper wire manufacturers to utilize post-consumer recycled copper to produce new wire. Upon receipt of copper cabling and wire from recyclers, the post-consumer wire products are sent through various pieces of equipment to strip the insulation, nylon, PVC, paper and other waste materials from the copper wire. The processing equipment shreds these materials into small, mostly uniform particles before they are collected by a dust collection cyclone. The material is metered via rotary airlock from the cyclone into a shafted screw conveyor. The screw conveyor then transports the waste material into roll-off dumpsters where it is discarded.

Encore Wire contacted KWS looking for a solution to material plugs and clogs in their current screw conveyor. Frequently, long strands of plastic would find a way through the system and into the screw conveyor. These strands would wrap around the centerpipe and flights of the shafted screw conveyor causing the conveyor to jam. Clearing these jams attributed to unwanted downtime and unscheduled maintenance costs. KWS offered a solution by eliminating the centerpipe and utilizing our shaftless screw conveyor technology.

Encore was also planning to upgrade the area by adding two additional roll-off dumpsters to keep up with the demand from increased processing capacity. To accommodate the new roll-off dumpsters, KWS and Encore decided to incorporate a second “piggyback” shaftless screw conveyor to transport the material to the inlets of the new dumpsters.

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

Transition Between New KWS Shaftless Screw Conveyors

Design Parameters of Application

  1. Product Type: PVC & Nylon Dust
  2. Material Density: 5 to 20 Lbs. per Cubic Foot
  3. Capacity: 143 Cubic Feet per Hour
  4. Duty: 24 Hours per Day, 7 Days per Week

Advantages Provided by KWS

An engineering team from KWS traveled to Encore Wire to gather critical dimensional information from the existing screw conveyor to determine the layout of the new replacement shaftless screw conveyor. During the site visit, the location of a second shaftless screw conveyor was determined to handle additional capacity. KWS engineers visited Encore Wire again during the approval drawing process to help Encore Wire engineers confirm proper installation angles, lengths, discharge and support locations to ensure installation would be simplified.

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

Existing Shafted Screw Conveyor Would Plug and Interrupt Production

Special Features of KWS Design

The KWS shaftless screw conveyors solved the clogging problem and eliminated any future unwanted downtime. The long strands of plastic were easily conveyed by the shaftless spiral. KWS chose oil-impregnated UHMW trough liners for the new shaftless screw conveyors. Because the shaftless spirals are in direct contact with the trough liners, liner wear is a natural occurrence. The oil-impregnated UHMW provides the required lubrication to aid in the reduction of liner wear when conveying a dry material.

KWS also designed and manufactured pneumatically operated slide gates for the intermediate discharges on the screw conveyors. The slide gates open to divert material flow into a particular roll-off dumpster. Once that dumpster has reached capacity the slide gate is closed so the material is conveyed to the next discharge point.

Testimonial

"The new system is performing great. We were able to increase production beyond our expectations."

Cliff Davis, Project Manager– Encore Wire Corporation (2017)

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

New KWS Shaftless Screw Conveyor Replaced Existing Shafted Screw Conveyor

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

New KWS Shaftless Screw Conveyor Eliminated Plugging Problems

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

Second Shaftless Conveyor with Multiple Discharge Locations

Screw Conveyor to Convey Recycled Wire Waste at Encore Wire in McKinney, TX - KWS

Scrap Plastic is Distributed to Three Different Dumpsters

Copper Scrap

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