Pellon Manure removal systems
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1 Pellon Manure removal systems Pellon Group Oy
2 Manure Master - the intelligen Pellon Manure Master is a revolutionary manure removal system for freestall barns. The system consists of urine draining profile, Manure Master drive unit, double wing scraper and control system. Each manure alley is equipped with a separate drive unit with individual operation schedules, obstacle sensitivity and driving modes. Wire traction drive unit without traditional wire drums reduces the wear and tear of the wire to a minimum. It also means that each alley can work independently from each other. Load cell readings from the drive unit enables unprecedented obstacle recognition sensitivity. The same cell also enables the user to see wire tension and so prevent wire extortion. Durable, simple and maintenance-friendly construction Remarkably small energy consumption compared to older systems Efficient urine separation keeps alleys dry and non-slippery as well as it reduces ammonia emission Superior sensitive operation, animal group specific obstacle detection Special area cleaning mode makes the system stress free also for more sensitive animals Integration with other barn automation like feeding systems Cleaning result is based on the best materials and design, not on heavy weight and high energy consumption Universal scraper wing construction. The same wings can be used regardless of the surface material, slope and cross-channel location The easy to use control system prevents execution of unwanted functions and prevents maintenance The free wheel of the wire is totally shielded and without any sharps parts above the floor 2
3 t manure removing system Sensitivity areas: Calving box = high 250 N Cow brush = medium 400 N Cubicle areas = low 550 N Manure load (automatic calculation) In operation Low scraper wings makes it easy for cows to pass the scraper Double wing construction gives the best cleaning result Cross channel location can be on one or both ends or in middle of the alley The 250W single unit can clean 120 m long and 4 m wide alleys. Operation modes Sensitivity areas All scraper alleys can have separate sensitivity settings to operate on selected areas in the most efficient way. The scraper cleans in a reliable way and works gently on areas close by milking robots, cow brushes and drinking bowls. Schedules Operation times can be set directly on the touch screen or operation can be set to continuous mode. Cleaning areas Scrapers cleaning calving or separation boxes can be programmed according to schedule or can be activated by remote control. This ensures safety and stressless condiotions for special animal groups. Integration to feeding Manure Master is integratable to automatic feeding systems or mixer wagons. Operation can be paused onselected times on alleys near by the feeding table. 3
4 Wire scraper Wire scraper for rubber mats There are three types of scrapers available for open alleys equipped with rubber mats edge wings or so called straight wings as well as a wing model for manure alleys with the cross channel in the middle. A scraper with straight wings is suitable to use in freestall barns with alleys less than 60m in length. Edge wing models are recommended for alleys over 60m, where cross channel is located at the end. Edge wing models can also be used in cold freestall barns, in which the manure is dryer. Rubber mat wings are equipped with an adjustable and replaceable sealing strip ensuring exceptionally well cleaned passages. Wings for open channels always require a guide in the middle of the manure alley. This is either a u-profile or a urine separation element. All open channel wings are hinged from the middle, so that the slope of the manure passage does not affect the function of the scraper. Wire scraper under the slats Three models of scrapers are available to be used under the slats. A painted model equipped with a forced-control wing mechanism is suitable for use in narrow and short channels. A robust galvanized model is suitable to use in long and wide channels. There is also a model available with rotating wings to be used in freestalls where the cross channel is not at the end. This model picks up manure from the end of the channel and drops it in the cross channel, while at the same time turning the wings in the other direction. Wire scraper on top of the slats 4
5 Control unit All wire scrapers have 24-hour clock function and the option of manual control. The obstacle detection is based either on a mechanical limit switch or motor current measurement. Some of the controls also have a frost function which will bypass the timer if the temperature falls below a set temperature. In this case the scraper will work either constantly or in short intervals in order to prevent freezing. Load cell based obstacle detection will be added to our traditional wire scrapers during Drive units The drive units are available in three different sizes depending on the length of the alleys. Alley length less than 60 m, motor 0.55 kw Alley length less than 90 m, motor 0.75 kw Alley length over 90 m, motor 0.9 kw All drive units have a hot-dip galvanized steel frame. The diameter of the wire drum is 200 mm, with the exception of the 0.9 kw drive unit, in which it is 250 mm. The drive unit is either mounted to a concrete wall or to the floor with its RHS-frame. The drive unit can be equipped with a wire guide which guides the wire evenly onto the wire drum. This increases the the life span of the wire. 5
6 Push Master multi The first Pellon hydraulic manure removal system was introduced in the 60 s. The renewed Push Master multi press is equipped with a closed piston that enables to move slurry from manure channels into the slurry pit. The closed piston principle prevents slurry from flowing back into the barn. The closed piston press system can also include an adaptor piece for mounting a round pipe on to the rectangular discharge tube. The adaptor can include bends in different directions so the slurry pit does not necessarily have to be right at the end of the manure channels. A scraper system with two or more wing balks can be used for short manure channels under slats. The scraper balks are welded together and the scraper wings on the balks bring the manure from the end of the channel to the collector channel. The last wing of the balk is a v-shaped end wing that picks up the manure right from the end of the channel. 6
7 Push Master single The Push Master single manure press features a press pipe as a straight extension to the manure channel. Manure is pressed to the storage right from the end of the manure channel and there is absolutely no need for a separate cross channel. Push Master single can be installed into cattle and pig barns as well as horse stables. Pellon Autohydro pump unit All Pellon Manure presses are equipped with an Pellon Autohydro valve that compensates for the pressure loss. The turning pressure can be adjusted with a manual valve from bar. The noise level of the pump unit is low even in reverse mode. Standard unit is equipped with oil level and temperature sensor. This ensures that the unit stops if oil level drops below minimum or temperature rises too high. Cylinders and hydraulic pipes Pellon Group relies on own manufacturing of hydraulic cylinders for the manure presses. Robot welding guarantees the uniform quality of the products. The cylinder arms are coated with KROMAKS treatment, that even outperforms double chroming. Control unit The manure press can be set to start automatically by a control cabinet equipped with a timer. In case you are using a Manure Master system with a Push Mater Multi as an extension, the Push Master can be operated with Manure Master control system and there is no need for a separate control centre. Work movement Return movement 7
8 Manure cooling system Cost efficiency with a heat pump A heat pump provides for efficient recovery of heat produced in barns. Utilisation of ground heat and slurry energy enables the owner to achieve remarkable savings compared to traditional heating. A system utilising a heat pump improves the living conditions of cows and the general conditions in the barn. Efficient heat collection Heat pump collects renewable energy from slurry and ground. Temperature released by the heat sources is relatively constant throughout the year and is concentrated with the heat pump technology. Cost savings due to the efficiency ratio of energy needed for working the heat pump and energy produced by the heat pump, i.e. thermal coefficient of performance is usually 2-4 times higher. The heat pump collects energy from the liquid solution in the heat collector circuits. The heat energy is raised to 100 degrees with compressor technology and then transported through the heat exchanger into a boiler. Collected energy is used for heating units, drinking water, sanitary water and for washing units. The Pellon farm energy recycling application controls optimal use of heat pumps, heat exchangers and heat recovery equipment. The size of the heat pump as well as the cooler and the superheater system is chosen according to the number of animals. Ammonia CO2 and CH4 emissions Minimising unwanted odours in animal buildings Relative ammonia concentration Temperature Source: Poul Pedersen Source: Anni Alitalo / MTT The effect of temperature on manure odour formation, according to Hügle and Andree (2001). Pellon Group Oy Tel Fax /14
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