ZEUS: The Disk Screw Press for Food & Beverage Sludge Dewatering
The Food & Beverage sector, including wine, juice, beer, cheese, preserved foods, meat-based products, etc., generates large quantities of wet waste and organic sludge every day. These materials are costly to transport and dispose of, take up considerable space and create management and hygiene challenges.
The ZEUS Disk Screw Press is the ideal monoblock solution for the Food & Beverage sector, designed for the thickening and mechanical dewatering of excess sludge, drastically reducing waste volumes and disposal costs. It is supplied complete with all the necessary equipment, including progressive cavity pumps, polyelectrolyte preparation station, flow meters and conveyors for transporting dewatered sludge.
Description
Depending on the model, ZEUS consists of one or more screw conveyors with a shaft running inside a duct made up of alternating fixed and moving discs, entirely manufactured in AISI 304 or 316L stainless steel. It is available in different power and flow rate configurations to adapt to the characteristics of each plant.
After conditioning in the dedicated flocculation tank, the sludge enters through the loading inlet, is conveyed by the spiral movement of the screw and then, as it advances, is progressively dewatered and compacted.
The movement between the fixed and moving discs promotes continuous self-cleaning of the machine and prevents clogging and blockage. Thanks to this system, the machine requires less washing water than other types of equipment used for sludge dewatering.
Why choose ZEUS
- Drastic reduction in disposal costs related to transport and disposal
- Self-cleaning system requiring very small quantities of washing water
- Reduced maintenance: no more machine downtime for manual washing and periodic cleaning thanks to the integrated self-cleaning system
- Automatic 24/7 operation: these presses are designed to ensure operational continuity without constant on-site intervention and integrate an advanced monitoring system that brings control directly to your smartphone or tablet
- Compact and modular design: easy installation and a complete system enclosed in a single package
- Superior structural strength: high-resistance materials to corrosion and wear, selected to withstand the most severe conditions over the long term
- AISI 304/316L materials suitable for food contact and HACCP requirements
- Low energy consumption: the presses operate with very low installed power, generally ranging from 0.55 kW to 7.5 kW depending on the model and required capacity
Applications
ZEUS supports beverage companies in managing sludge generated by processing operations, from winemaking to the production of beverages and beer.
The sectors involved include, for example, the wine industry, with wine lees, the beverage sector, where fruit pressing waste is treated, and the brewing industry, dealing with spent brewer's grains and exhausted yeast.
In the food sector too, the amount of organic waste generated during food processing often represents a challenge, both in terms of space and hygiene. ZEUS can be used, for example, in the dairy sector for whey, in meat processing for slaughterhouse residues, and in vegetable preservation for vegetable peeling and cooking waste.
Integrated Approach
SCAE does not simply supply a machine, but an integrated approach that makes the sludge dewatering process stable and efficient over time.
In addition to the Disk Press, SCAE supplies:
- Polyelectrolyte preparation unit: Proper preparation of the polyelectrolyte solution is crucial to the efficiency of the entire process. The SCAE polyelectrolyte preparation unit provides a homogeneous solution with controlled concentration, ensuring optimal sludge flocculation before entering the press.
- Polyelectrolyte: SCAE also supports the customer in selecting the most suitable polyelectrolyte for the specific type of sludge in the plant; the choice of the correct polymer - in terms of charge, molecular weight and physical form - directly affects dewatering performance and overall reagent consumption.
- Service: SCAE technical support does not end with the supply. The specialised team provides support during start-up, optimisation of operating parameters and scheduled maintenance, ensuring continuity of operation and preserving machine performance over the long term.
Mobile ZEUS Unit
• Operative Rental: On mobile units, ideal for managing temporary needs, line revamping or seasonal production peaks.
• Containerised solutions: In customisable units/containers that can be installed without authorisation procedures or structural works, for those seeking a stable operational solution that can be activated quickly.
Each mobile unit is a complete system including the ZEUS Disk Screw Press, sludge feed pump, automatic polyelectrolyte preparation unit with the relevant chemicals, flow meters and screw conveyor system for managing dewatered sludge. The units are fully automated and remotely monitored via SCAE SMART NET 4.0.
The equipment is configured and, where necessary, serviced directly by SCAE throughout all stages of the service. Upon request, a hot rental service is also available, with specialised process technicians to operate the system.
Sustainability
The ZEUS Disk Screw Press is not only an advanced technological solution, but also makes a tangible contribution to the ecological transition of Food & Beverage companies. By drastically reducing sludge volume, it significantly decreases the number of transports required to disposal facilities, resulting in a substantial reduction in CO2 emissions
Dewatered sludge, being much drier and more compact, becomes easier to handle, store and direct towards recovery pathways (material or energy recovery, depending on applicable regulations) rather than simply being sent to landfill. This makes it possible to turn a cost into a potential resource.
Furthermore, thanks to its very low washing water consumption and reduced energy requirements (very low installed power), ZEUS delivers significant water and energy savings, two increasingly strategic factors for companies committed to environmental sustainability and reducing their impact on the surrounding area.
CHECK PLANT COMPATIBILITY
Not sure whether your plant is compatible with this solution? We can help!
You can book a pilot test directly at your plant. Our technical team will analyse the characteristics of your process residues and show you, based on actual data, the real results that the SCAE-ZEUS system can achieve
What you get with the pilot test:
• Temporary installation of the machine at your site;
• Performance analysis on real sludge (your plant, your conditions);
• Technical report with the dewatering level achieved and estimated savings.
We give you the opportunity to verify compatibility in the field before making any decision regarding an investment.
